Expandable Tubular

ABSTRACT

An expandable tubular.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is the U.S. National Stage application for PCTapplication serial no. PCT/US2004/028888, attorney docket no.25791.305.02, filed on Sep. 7, 2004, which claimed the benefit of: (1)U.S. provisional patent application Ser. No. 60/600,679, attorney docketno 25791.194, filed on Aug. 11, 2004, (2) U.S. provisional patentapplication Ser. No. 60/585,370, attorney docket no 25791.299, filed onJul. 2, 2004, and (3) U.S. provisional patent application serial no.60/500,435, attorney docket no 25791.304, filed on Sep. 5, 2003, thedisclosures of which are incorporated herein by reference.

The application is a continuation-in-part of U.S. utility patentapplication Ser. No. 10/528,498, attorney docket no. 25791.118.08, filedon Mar. 18, 2005, which was the National Stage for PCT applicationserial no. PCT/US03/025667, attorney docket no. 25791.118.02, filed onAug. 18, 2003, which claimed the benefit of the filing date of U.S.provisional patent application Ser. No. 60/412,653, attorney docket25791.118, filed on Sep. 20, 2002, the disclosures of which areincorporated herein by reference.

This application is related to the following co-pending applications:(1) U.S. National State patent application Ser. No. ______, attorneydocket no. 25791.304.10, filed on Mar. 2, 2006; (2) U.S. National Statepatent application Ser. No. ______, attorney docket no. 25791.306.04,filed on _; (3) U.S. National State patent application Ser. No. ______,attorney docket no. 25791.307.04, filed on _; and (4) U.S. NationalState patent application Ser. No. ______, attorney docket no.25791.308.07, filed on _, the disclosures of which are incorporatedherein by reference.

This application is related to the following co-pending applications:(1) U.S. Pat. No. 6,497,289, which was filed as U.S. patent applicationSer. No. 09/454,139, attorney docket no. 25791.03.02, filed on Dec. 3,1999, which claims priority from provisional application 60/111,293,filed on Dec. 7, 1998, (2) U.S. patent application Ser. No. 09/510,913,attorney docket no. 25791.7.02, filed on Feb. 23, 2000, which claimspriority from provisional application 60/121,702, filed on Feb. 25,1999, (3) U.S. patent application Ser. No. 09/502,350, attorney docketno. 25791.8.02, filed on Feb. 10, 2000, which claims priority fromprovisional application 60/119,611, filed on Feb. 11, 1999, (4) U.S.Pat. No. 6,328,113, which was filed as U.S. patent application Ser. No.09/440,338, attorney docket number 25791.9.02, filed on Nov. 15, 1999,which claims priority from provisional application 60/108,558, filed onNov. 16, 1998, (5) U.S. patent application Ser. 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BACKGROUND OF THE INVENTION

This invention relates generally to oil and gas exploration, and inparticular to forming and repairing wellbore casings to facilitate oiland gas exploration.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a fragmentary cross sectional view of an exemplary embodimentof an expandable tubular member positioned within a preexistingstructure.

FIG. 2 is a fragmentary cross sectional view of the expandable tubularmember of FIG. 1 after positioning an expansion device within theexpandable tubular member.

FIG. 3 is a fragmentary cross sectional view of the expandable tubularmember of FIG. 2 after operating the expansion device within theexpandable tubular member to radially expand and plastically deform aportion of the expandable tubular member.

FIG. 4 is a fragmentary cross sectional view of the expandable tubularmember of FIG. 3 after operating the expansion device within theexpandable tubular member to radially expand and plastically deformanother portion of the expandable tubular member.

FIG. 5 is a graphical illustration of exemplary embodiments of thestress/strain curves for several portions of the expandable tubularmember of FIGS. 1-4.

FIG. 6 is a graphical illustration of the exemplary embodiment of theyield strength vs. ductility curve for at least a portion of theexpandable tubular member of FIGS. 1-4.

FIG. 7 is a fragmentary cross sectional illustration of an embodiment ofa series of overlapping expandable tubular members.

FIG. 8 is a fragmentary cross sectional view of an exemplary embodimentof an expandable tubular member positioned within a preexistingstructure.

FIG. 9 is a fragmentary cross sectional view of the expandable tubularmember of FIG. 8 after positioning an expansion device within theexpandable tubular member.

FIG. 10 is a fragmentary cross sectional view of the expandable tubularmember of FIG. 9 after operating the expansion device within theexpandable tubular member to radially expand and plastically deform aportion of the expandable tubular member.

FIG. 11 is a fragmentary cross sectional view of the expandable tubularmember of FIG. 10 after operating the expansion device within theexpandable tubular member to radially expand and plastically deformanother portion of the expandable tubular member.

FIG. 12 is a graphical illustration of exemplary embodiments of thestress/strain curves for several portions of the expandable tubularmember of FIGS. 8-11.

FIG. 13 is a graphical illustration of an exemplary embodiment of theyield strength vs. ductility curve for at least a portion of theexpandable tubular member of FIGS. 8-11.

FIG. 14 is a fragmentary cross sectional view of an exemplary embodimentof an expandable tubular member positioned within a preexistingstructure.

FIG. 15 is a fragmentary cross sectional view of the expandable tubularmember of FIG. 14 after positioning an expansion device within theexpandable tubular member.

FIG. 16 is a fragmentary cross sectional view of the expandable tubularmember of FIG. 15 after operating the expansion device within theexpandable tubular member to radially expand and plastically deform aportion of the expandable tubular member.

FIG. 17 is a fragmentary cross sectional view of the expandable tubularmember of FIG. 16 after operating the expansion device within theexpandable tubular member to radially expand and plastically deformanother portion of the expandable tubular member.

FIG. 18 is a flow chart illustration of an exemplary embodiment of amethod of processing an expandable tubular member.

FIG. 19 is a graphical illustration of the an exemplary embodiment ofthe yield strength vs. ductility curve for at least a portion of theexpandable tubular member during the operation of the method of FIG. 18.

FIG. 20 is a graphical illustration of stress/strain curves for anexemplary embodiment of an expandable tubular member.

FIG. 21 is a graphical illustration of stress/strain curves for anexemplary embodiment of an expandable tubular member.

FIG. 22 is a fragmentary cross-sectional view illustrating an embodimentof the radial expansion and plastic deformation of a portion of a firsttubular member having an internally threaded connection at an endportion, an embodiment of a tubular sleeve supported by the end portionof the first tubular member, and a second tubular member having anexternally threaded portion coupled to the internally threaded portionof the first tubular member and engaged by a flange of the sleeve. Thesleeve includes the flange at one end for increasing axial compressionloading.

FIG. 23 is a fragmentary cross-sectional view illustrating an embodimentof the radial expansion and plastic deformation of a portion of a firsttubular member having an internally threaded connection at an endportion, a second tubular member having an externally threaded portioncoupled to the internally threaded portion of the first tubular member,and an embodiment of a tubular sleeve supported by the end portion ofboth tubular members. The sleeve includes flanges at opposite ends forincreasing axial tension loading.

FIG. 24 is a fragmentary cross-sectional illustration of the radialexpansion and plastic deformation of a portion of a first tubular memberhaving an internally threaded connection at an end portion, a secondtubular member having an externally threaded portion coupled to theinternally threaded portion of the first tubular member, and anembodiment of a tubular sleeve supported by the end portion of bothtubular members. The sleeve includes flanges at opposite ends forincreasing axial compression/tension loading.

FIG. 25 is a fragmentary cross-sectional illustration of the radialexpansion and plastic deformation of a portion of a first tubular memberhaving an internally threaded connection at an end portion, a secondtubular member having an externally threaded portion coupled to theinternally threaded portion of the first tubular member, and anembodiment of a tubular sleeve supported by the end portion of bothtubular members. The sleeve includes flanges at opposite ends havingsacrificial material thereon.

FIG. 26 is a fragmentary cross-sectional illustration of the radialexpansion and plastic deformation of a portion of a first tubular memberhaving an internally threaded connection at an end portion, a secondtubular member having an externally threaded portion coupled to theinternally threaded portion of the first tubular member, and anembodiment of a tubular sleeve supported by the end portion of bothtubular members. The sleeve includes a thin walled cylinder ofsacrificial material.

FIG. 27 is a fragmentary cross-sectional illustration of the radialexpansion and plastic deformation of a portion of a first tubular memberhaving an internally threaded connection at an end portion, a secondtubular member having an externally threaded portion coupled to theinternally threaded portion of the first tubular member, and anembodiment of a tubular sleeve supported by the end portion of bothtubular members. The sleeve includes a variable thickness along thelength thereof.

FIG. 28 is a fragmentary cross-sectional illustration of the radialexpansion and plastic deformation of a portion of a first tubular memberhaving an internally threaded connection at an end portion, a secondtubular member having an externally threaded portion coupled to theinternally threaded portion of the first tubular member, and anembodiment of a tubular sleeve supported by the end portion of bothtubular members. The sleeve includes a member coiled onto grooves formedin the sleeve for varying the sleeve thickness.

FIG. 29 is a fragmentary cross-sectional illustration of an exemplaryembodiment of an expandable connection.

FIGS. 30 a-30 c are fragmentary cross-sectional illustrations ofexemplary embodiments of expandable connections.

FIG. 31 is a fragmentary cross-sectional illustration of an exemplaryembodiment of an expandable connection.

FIGS. 32 a and 32 b are fragmentary cross-sectional illustrations of theformation of an exemplary embodiment of an expandable connection.

FIG. 33 is a fragmentary cross-sectional illustration of an exemplaryembodiment of an expandable connection.

FIGS. 34 a, 34 b and 34 c are fragmentary cross-sectional illustrationsof an exemplary embodiment of an expandable connection.

FIG. 35 a is a fragmentary cross-sectional illustration of an exemplaryembodiment of an expandable tubular member.

FIG. 35 b is a graphical illustration of an exemplary embodiment of thevariation in the yield point for the expandable tubular member of FIG.35 a.

FIG. 36 a is a flow chart illustration of an exemplary embodiment of amethod for processing a tubular member.

FIG. 36 b is an illustration of the microstructure of an exemplaryembodiment of a tubular member prior to thermal processing.

FIG. 36 c is an illustration of the microstructure of an exemplaryembodiment of a tubular member after thermal processing.

FIG. 37 a is a flow chart illustration of an exemplary embodiment of amethod for processing a tubular member.

FIG. 37 b is an illustration of the microstructure of an exemplaryembodiment of a tubular member prior to thermal processing.

FIG. 37 c is an illustration of the microstructure of an exemplaryembodiment of a tubular member after thermal processing.

FIG. 38 a is a flow chart illustration of an exemplary embodiment of amethod for processing a tubular member.

FIG. 38 b is an illustration of the microstructure of an exemplaryembodiment of a tubular member prior to thermal processing.

FIG. 38 c is an illustration of the microstructure of an exemplaryembodiment of a tubular member after thermal processing.

FIG. 39 a is an illustration of exemplary tribological elements in asystem for lubricating the interface between the expansion cone and atubular member during the radial expansion and plastic deformation ofthe tubular member.

FIG. 39 b is a fragmentary cross-sectional illustration of thelubrication of the interface between an expansion cone and a tubularmember during the radial expansion process.

FIG. 40 is an illustration of an embodiment of an expansion coneincluding a system for lubricating the interface between the expansioncone and a tubular member during the radial expansion and plasticdeformation of the tubular member.

FIG. 41 is an illustration of an embodiment of an expansion coneincluding a system for lubricating the interface between the expansioncone and a tubular member during the radial expansion and plasticdeformation of the tubular member.

FIG. 42 is an illustration of an embodiment of an expansion coneincluding a system for lubricating the interface between the expansioncone and a tubular member during the radial expansion and plasticdeformation of the tubular member.

FIG. 43 is an illustration of an embodiment of an expansion coneincluding a system for lubricating the interface between the expansioncone and a tubular member during the radial expansion and plasticdeformation of the tubular member.

FIG. 44 is an illustration of an embodiment of an expansion coneincluding a system for lubricating the interface between the expansioncone and a tubular member during the radial expansion and plasticdeformation of the tubular member.

FIG. 45 is an illustration of an embodiment of an expansion coneincluding a system for lubricating the interface between the expansioncone and a tubular member during the radial expansion and plasticdeformation of the tubular member.

FIG. 46 is an illustration of an embodiment of an expansion coneincluding a system for lubricating the interface between the expansioncone and a tubular member during the radial expansion and plasticdeformation of the tubular member.

FIG. 47 is an illustration of an embodiment of an expansion coneincluding a system for lubricating the interface between the expansioncone and a tubular member during the radial expansion and plasticdeformation of the tubular member.

FIG. 48 is an illustration of an embodiment of an expansion coneincluding a system for lubricating the interface between the expansioncone and a tubular member during the radial expansion and plasticdeformation of the tubular member.

FIG. 49 is an illustration of an embodiment of an expansion coneincluding a system for lubricating the interface between the expansioncone and a tubular member during the radial expansion and plasticdeformation of the tubular member.

FIG. 50 is an illustration of an embodiment of an expansion coneincluding a system for lubricating the interface between the expansioncone and a tubular member during the radial expansion and plasticdeformation of the tubular member.

FIG. 51 is an illustration of an embodiment of an expansion coneincluding a system for lubricating the interface between the expansioncone and a tubular member during the radial expansion and plasticdeformation of the tubular member.

FIG. 52 is an illustration of an embodiment of an expansion coneincluding a system for lubricating the interface between the expansioncone and a tubular member during the radial expansion and plasticdeformation of the tubular member.

FIG. 53 is an illustration of an embodiment of an expansion coneincluding a system for lubricating the interface between the expansioncone and a tubular member during the radial expansion and plasticdeformation of the tubular member.

FIG. 54 is an illustration of an embodiment of an expansion coneincluding a system for lubricating the interface between the expansioncone and a tubular member during the radial expansion and plasticdeformation of the tubular member.

FIG. 55 is a cross-sectional illustration of a circumferential groovesuitable for use with the expansion cones of FIGS. 40-54.

FIG. 56 is an illustration of the groove of FIG. 55.

FIG. 57 is an illustration of an alternate embodiment of thecircumferential grove of the expansion cones of FIGS. 40-57.

FIG. 58 a is an elevational view of an embodiment of an expansion coneincluding a system for lubricating the interface between the expansioncone and a tubular member during the radial expansion and plasticdeformation of the tubular member utilizing a groove designed inaccordance with FIG. 57.

FIG. 58 b is a top view of the expansion cone of FIG. 58 a.

FIG. 58 c is an enlarged section of the expansion cone of FIG. 58 a.

FIG. 59 a is an illustration of an embodiment of an expansion coneincluding a system for lubricating the interface between the expansioncone and a tubular member during the radial expansion and plasticdeformation of the tubular member.

FIG. 59 b is a top view of the expansion cone of FIG. 59 a.

FIG. 60 a is an illustration of an embodiment of an expansion coneincluding a system for lubricating the interface between the expansioncone having a tapered faceted polygonal outer expansion surface and atubular member during the radial expansion and plastic deformation ofthe tubular member.

FIG. 60 b is a top view of the expansion cone in FIG. 60 a.

FIG. 60 c is a fragmentary cross-sectional illustration of the expansioncone in FIG. 60 a in a tubular member.

FIGS. 61 a and 61 b are cross-sectional illustrations of an alternateembodiment of tubular member and an expansion cone including a systemfor lubricating the interface between the expansion cone having atapered faceted polygonal outer expansion surface and a tubular memberduring the radial expansion and plastic deformation of the tubularmember.

FIGS. 61 c and 61 d are cross-sectional illustrations of an alternateembodiment of an expansion cone including a system for lubricating theinterface between the expansion cone having a tapered faceted polygonalouter expansion surface and a tubular member during the radial expansionand plastic deformation of the tubular member.

FIG. 61 e is cross-sectional illustrations of an alternate embodiment ofan expansion cone including a system for lubricating the interfacebetween the expansion cone having a tapered faceted polygonal outerexpansion surface and a tubular member having non-uniform wall thicknessduring the radial expansion and plastic deformation of the tubularmember.

FIG. 62 a, 62 b, and 62 c are an illustrations of an alternateembodiment of an expansion cone including a system for lubricating theinterface between the expansion cone having a tapered faceted polygonalouter expansion surface and a tubular member during the radial expansionand plastic deformation of the tubular member.

FIG. 62 d, 62 e, and 62 f are an illustrations of an alternateembodiment of an expansion cone including a system for lubricating theinterface between the expansion cone having a tapered faceted polygonalouter expansion surface and a tubular member during the radial expansionand plastic deformation of the tubular member.

FIG. 63 is a cross-sectional illustration of an embodiment of a systemfor lubricating the interface between the expansion cone and a tubularmember during the radial expansion and plastic deformation of thetubular member.

FIG. 64 is a cross-sectional illustration of an embodiment of a systemfor lubricating the interface between the expansion cone and a tubularmember during the radial expansion and plastic deformation of thetubular member.

FIG. 65 is a cross-sectional illustration of an embodiment of a systemfor lubricating the interface between the expansion cone and a tubularmember during the radial expansion and plastic deformation of thetubular member.

FIG. 66 is a cross-sectional illustration of an embodiment of a systemfor lubricating the interface between the expansion cone and a tubularmember during the radial expansion and plastic deformation of thetubular member.

FIG. 67 is a cross-sectional illustration of an embodiment of a systemfor lubricating the interface between the expansion cone and a tubularmember during the radial expansion and plastic deformation of thetubular member.

FIG. 68 is a cross-sectional illustration of an embodiment of a systemfor lubricating the interface between the expansion cone and a tubularmember during the radial expansion and plastic deformation of thetubular member.

FIG. 69 is a cross-sectional illustration of an embodiment of a systemfor lubricating the interface between the expansion cone and a tubularmember during the radial expansion and plastic deformation of thetubular member.

FIG. 70 is a cross-sectional illustration of an embodiment of a systemfor lubricating the interface between the expansion cone and a tubularmember during the radial expansion and plastic deformation of thetubular member.

FIGS. 71 a, 71 b, 71 c, 71 d and 71 e are graphical illustrations ofexample expansion cone materials characteristics.

FIG. 72 is a flow chart illustration of an exemplary embodiment of amethod for processing a tubular member.

FIG. 73 a is a fragmentary cross-sectional illustration of examplefrictional forces in a system including an expansion cone and a tubularmember during the radial expansion and plastic deformation of thetubular member.

FIG. 73 b is a fragmentary cross-sectional illustration of an examplecomponents in a system including an expansion cone and a tubular memberduring the radial expansion and plastic deformation of the tubularmember that contribute to the frictional forces.

FIGS. 73 c and 73 d are fragmentary cross-sectional illustrations ofexample expansion cone surface roughness and texture characteristics ina system including an expansion cone and a tubular member during theradial expansion and plastic deformation of the tubular member thatcontribute to the frictional forces.

FIG. 74 is a graphical illustration of a coefficient of friction versusexpansion force in an exemplary system for radially expanding a tubularmember.

FIG. 75 is a graphical logarithmic illustration of the coefficient offriction versus expansion force (in pounds per square inch) in anexemplary system for radially expanding a tubular member.

FIG. 76 is a graphical logarithmic illustration of the coefficient offriction versus expansion force (in pounds) in an exemplary system forradially expanding a tubular member.

FIG. 77 is a graphical illustration of the expansion forces in anexemplary system for radially expanding a tubular member over time.

FIG. 78 is a graphical illustration the range of coefficients offriction for exemplary systems for radially expanding a tubular member.

FIGS. 79 a and 79 b are photo-micrograph illustrations of themicrostructure of an exemplary embodiments of expansion cones.

FIGS. 80 a and 80 b are photo-micrograph illustrations of themicrostructure of the exemplary embodiments of expansion cones shown inFIGS. 79 a and 79 b, respectively.

FIGS. 81 a and 81 b are graphical illustrations of the x-profile of theexemplary embodiments of expansion cones shown in FIGS. 79 a and 79 b,respectively.

FIGS. 82 a and 82 b are graphical illustrations of the bearing ratio ofthe exemplary embodiments of expansion cones shown in FIGS. 79 a and 79b, respectively.

FIGS. 83 a and 83 b are photo-micrograph illustrations of themicrostructure of an exemplary embodiments of expansion cones.

FIGS. 84 a and 84 b are photo-micrograph illustrations of themicrostructure of the exemplary embodiments of expansion cones shown inFIGS. 83 a and 83 b, respectively.

FIGS. 85 a and 85 b are graphical illustrations of the x-profile of theexemplary embodiments of expansion cones shown in FIGS. 83 a and 83 b,respectively.

FIGS. 86 a and 86 b are graphical illustrations of the bearing ratio ofthe exemplary embodiments of expansion cones shown in FIGS. 83 a and 83b, respectively.

FIG. 87 is a graphical illustration ranges of expansion forcesassociated with exemplary systems for radially expanding a tubularmember.

FIG. 88 is a graphical illustration ranges of expansion forcesassociated with exemplary systems for radially expanding a tubularmember.

FIG. 89 is a graphical illustration ranges of expansion forcesassociated with exemplary systems for radially expanding a tubularmember.

FIG. 90 is a graphical illustration ranges of expansion forcesassociated with exemplary systems for radially expanding a tubularmember.

FIG. 91 is a graphical illustration ranges of expansion forcesassociated with exemplary systems for radially expanding a tubularmember.

FIG. 92 is a graphical illustration ranges of expansion forcesassociated with exemplary systems for radially expanding a tubularmember.

FIG. 93 is a graphical illustration ranges of expansion forcesassociated with exemplary systems for radially expanding a tubularmember.

FIG. 94 is a graphical illustration ranges of expansion forcesassociated with exemplary systems for radially expanding a tubularmember.

FIG. 95 is a graphical illustration ranges of expansion forcesassociated with exemplary systems for radially expanding a tubularmember.

FIG. 96 is a graphical illustration ranges of expansion forcesassociated with exemplary systems for radially expanding a tubularmember.

FIG. 97 is a graphical illustration ranges of expansion forcesassociated with exemplary systems for radially expanding a tubularmember.

FIG. 98 is a graphical illustration ranges of expansion forcesassociated with exemplary systems for radially expanding a tubularmember.

FIG. 99 a is an illustration of an embodiment of an expansion coneincluding a system for lubricating the interface between the expansioncone and a tubular member during the radial expansion and plasticdeformation of the tubular member.

FIG. 99 b are photo-micrograph illustrations of the microstructure of anexemplary embodiments of expansion cones.

FIG. 99 c is an illustration of an embodiment of a system forlubricating the interface between the expansion cone and a tubularmember during the radial expansion and plastic deformation of thetubular member.

FIG. 100 is a schematic fragmentary cross-sectional view along a planealong and through the central axis of a tubular member that is tested tofailure with axial opposed forces.

FIG. 101 is a stress-strain curve representing values for stress andstrain that may be plotted for solid specimen sample.

FIG. 102 is a schematically depiction of a stress strain curverepresenting values from an exemplary test on a tubular member.

FIG. 103 is a graphical illustration of an exemplary experimentalembodiment.

FIG. 104 is a graphical illustration of an exemplary experimentalembodiment.

FIG. 105 is a flow chart illustration of an exemplary embodiment of amethod of processing tubular members.

FIG. 106 is a graphical illustration of an exemplary embodiment of amethod of processing tubular members.

FIG. 107 is a graphical illustration of an exemplary embodiment of amethod of processing tubular members.

FIG. 108 is a graphical illustration of an exemplary embodiment of amethod of processing tubular members.

DETAILED DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS

Referring initially to FIG. 1, an exemplary embodiment of an expandabletubular assembly 10 includes a first expandable tubular member 12coupled to a second expandable tubular member 14. In several exemplaryembodiments, the ends of the first and second expandable tubularmembers, 12 and 14, are coupled using, for example, a conventionalmechanical coupling, a welded connection, a brazed connection, athreaded connection, and/or an interference fit connection. In anexemplary embodiment, the first expandable tubular member 12 has aplastic yield point YP₁, and the second expandable tubular member 14 hasa plastic yield point YP₂. In an exemplary embodiment, the expandabletubular assembly 10 is positioned within a preexisting structure suchas, for example, a wellbore 16 that traverses a subterranean formation18.

As illustrated in FIG. 2, an expansion device 20 may then be positionedwithin the second expandable tubular member 14. In several exemplaryembodiments, the expansion device 20 may include, for example, one ormore of the following conventional expansion devices: a) an expansioncone; b) a rotary expansion device; c) a hydroforming expansion device;d) an impulsive force expansion device; d) any one of the expansiondevices commercially available from, or disclosed in any of thepublished patent applications or issued patents, of WeatherfordInternational, Baker Hughes, Halliburton Energy Services, Shell Oil Co.,Schlumberger, and/or Enventure Global Technology L.L.C. In severalexemplary embodiments, the expansion device 20 is positioned within thesecond expandable tubular member 14 before, during, or after theplacement of the expandable tubular assembly 10 within the preexistingstructure 16.

As illustrated in FIG. 3, the expansion device 20 may then be operatedto radially expand and plastically deform at least a portion of thesecond expandable tubular member 14 to form a bell-shaped section.

As illustrated in FIG. 4, the expansion device 20 may then be operatedto radially expand and plastically deform the remaining portion of thesecond expandable tubular member 14 and at least a portion of the firstexpandable tubular member 12.

In an exemplary embodiment, at least a portion of at least a portion ofat least one of the first and second expandable tubular members, 12 and14, are radially expanded into intimate contact with the interiorsurface of the preexisting structure 16.

In an exemplary embodiment, as illustrated in FIG. 5, the plastic yieldpoint YP₁ is greater than the plastic yield point YP₂. In this manner,in an exemplary embodiment, the amount of power and/or energy requiredto radially expand the second expandable tubular member 14 is less thanthe amount of power and/or energy required to radially expand the firstexpandable tubular member 12.

In an exemplary embodiment, as illustrated in FIG. 6, the firstexpandable tubular member 12 and/or the second expandable tubular member14 have a ductility D_(PE) and a yield strength YS_(PE) prior to radialexpansion and plastic deformation, and a ductility D_(AE) and a yieldstrength YS_(AE) after radial expansion and plastic deformation. In anexemplary embodiment, D_(PE) is greater than D_(AE), and YS_(AE) isgreater than YS_(PE). In this manner, the first expandable tubularmember 12 and/or the second expandable tubular member 14 are transformedduring the radial expansion and plastic deformation process.Furthermore, in this manner, in an exemplary embodiment, the amount ofpower and/or energy required to radially expand each unit length of thefirst and/or second expandable tubular members, 12 and 14, is reduced.Furthermore, because the YS_(AE) is greater than YS_(PE), the collapsestrength of the first expandable tubular member 12 and/or the secondexpandable tubular member 14 is increased after the radial expansion andplastic deformation process.

In an exemplary embodiment, as illustrated in FIG. 7, following thecompletion of the radial expansion and plastic deformation of theexpandable tubular assembly 10 described above with reference to FIGS.1-4, at least a portion of the second expandable tubular member 14 hasan inside diameter that is greater than at least the inside diameter ofthe first expandable tubular member 12. In this manner a bell-shapedsection is formed using at least a portion of the second expandabletubular member 14. Another expandable tubular assembly 22 that includesa first expandable tubular member 24 and a second expandable tubularmember 26 may then be positioned in overlapping relation to the firstexpandable tubular assembly 10 and radially expanded and plasticallydeformed using the methods described above with reference to FIGS. 1-4.Furthermore, following the completion of the radial expansion andplastic deformation of the expandable tubular assembly 20, in anexemplary embodiment, at least a portion of the second expandabletubular member 26 has an inside diameter that is greater than at leastthe inside diameter of the first expandable tubular member 24. In thismanner a bell-shaped section is formed using at least a portion of thesecond expandable tubular member 26. Furthermore, in this manner, amono-diameter tubular assembly is formed that defines an internalpassage 28 having a substantially constant cross-sectional area and/orinside diameter.

Referring to FIG. 8, an exemplary embodiment of an expandable tubularassembly 100 includes a first expandable tubular member 102 coupled to atubular coupling 104. The tubular coupling 104 is coupled to a tubularcoupling 106. The tubular coupling 106 is coupled to a second expandabletubular member 108. In several exemplary embodiments, the tubularcouplings, 104 and 106, provide a tubular coupling assembly for couplingthe first and second expandable tubular members, 102 and 108, togetherthat may include, for example, a conventional mechanical coupling, awelded connection, a brazed connection, a threaded connection, and/or aninterference fit connection. In an exemplary embodiment, the first andsecond expandable tubular members 12 have a plastic yield point YP₁, andthe tubular couplings, 104 and 106, have a plastic yield point YP₂. Inan exemplary embodiment, the expandable tubular assembly 100 ispositioned within a preexisting structure such as, for example, awellbore 110 that traverses a subterranean formation 112.

As illustrated in FIG. 9, an expansion device 114 may then be positionedwithin the second expandable tubular member 108. In several exemplaryembodiments, the expansion device 114 may include, for example, one ormore of the following conventional expansion devices: a) an expansioncone; b) a rotary expansion device; c) a hydroforming expansion device;d) an impulsive force expansion device; d) any one of the expansiondevices commercially available from, or disclosed in any of thepublished patent applications or issued patents, of WeatherfordInternational, Baker Hughes, Halliburton Energy Services, Shell Oil Co.,Schlumberger, and/or Enventure Global Technology L.L.C. In severalexemplary embodiments, the expansion device 114 is positioned within thesecond expandable tubular member 108 before, during, or after theplacement of the expandable tubular assembly 100 within the preexistingstructure 110.

As illustrated in FIG. 10, the expansion device 114 may then be operatedto radially expand and plastically deform at least a portion of thesecond expandable tubular member 108 to form a bell-shaped section.

As illustrated in FIG. 11, the expansion device 114 may then be operatedto radially expand and plastically deform the remaining portion of thesecond expandable tubular member 108, the tubular couplings, 104 and106, and at least a portion of the first expandable tubular member 102.

In an exemplary embodiment, at least a portion of at least a portion ofat least one of the first and second expandable tubular members, 102 and108, are radially expanded into intimate contact with the interiorsurface of the preexisting structure 110.

In an exemplary embodiment, as illustrated in FIG. 12, the plastic yieldpoint YP₁ is less than the plastic yield point YP₂. In this manner, inan exemplary embodiment, the amount of power and/or energy required toradially expand each unit length of the first and second expandabletubular members, 102 and 108, is less than the amount of power and/orenergy required to radially expand each unit length of the tubularcouplings, 104 and 106.

In an exemplary embodiment, as illustrated in FIG. 13, the firstexpandable tubular member 12 and/or the second expandable tubular member14 have a ductility D_(PE) and a yield strength YS_(PE) prior to radialexpansion and plastic deformation, and a ductility D_(AE) and a yieldstrength YS_(AE) after radial expansion and plastic deformation. In anexemplary embodiment, D_(PE) is greater than D_(AE), and YS_(AE) isgreater than YS_(PE). In this manner, the first expandable tubularmember 12 and/or the second expandable tubular member 14 are transformedduring the radial expansion and plastic deformation process.Furthermore, in this manner, in an exemplary embodiment, the amount ofpower and/or energy required to radially expand each unit length of thefirst and/or second expandable tubular members, 12 and 14, is reduced.Furthermore, because the YS_(AE) is greater than YS_(PE), the collapsestrength of the first expandable tubular member 12 and/or the secondexpandable tubular member 14 is increased after the radial expansion andplastic deformation process.

Referring to FIG. 14, an exemplary embodiment of an expandable tubularassembly 200 includes a first expandable tubular member 202 coupled to asecond expandable tubular member 204 that defines radial openings 204 a,204 b, 204 c, and 204 d. In several exemplary embodiments, the ends ofthe first and second expandable tubular members, 202 and 204, arecoupled using, for example, a conventional mechanical coupling, a weldedconnection, a brazed connection, a threaded connection, and/or aninterference fit connection. In an exemplary embodiment, one or more ofthe radial openings, 204 a, 204 b, 204 c, and 204 d, have circular,oval, square, and/or irregular cross sections and/or include portionsthat extend to and interrupt either end of the second expandable tubularmember 204. In an exemplary embodiment, the expandable tubular assembly200 is positioned within a preexisting structure such as, for example, awellbore 206 that traverses a subterranean formation 208.

As illustrated in FIG. 15, an expansion device 210 may then bepositioned within the second expandable tubular member 204. In severalexemplary embodiments, the expansion device 210 may include, forexample, one or more of the following conventional expansion devices: a)an expansion cone; b) a rotary expansion device; c) a hydroformingexpansion device; d) an impulsive force expansion device; d) any one ofthe expansion devices commercially available from, or disclosed in anyof the published patent applications or issued patents, of WeatherfordInternational, Baker Hughes, Halliburton Energy Services, Shell Oil Co.,Schlumberger, and/or Enventure Global Technology L.L.C. In severalexemplary embodiments, the expansion device 210 is positioned within thesecond expandable tubular member 204 before, during, or after theplacement of the expandable tubular assembly 200 within the preexistingstructure 206.

As illustrated in FIG. 16, the expansion device 210 may then be operatedto radially expand and plastically deform at least a portion of thesecond expandable tubular member 204 to form a bell-shaped section.

As illustrated in FIG. 16, the expansion device 20 may then be operatedto radially expand and plastically deform the remaining portion of thesecond expandable tubular member 204 and at least a portion of the firstexpandable tubular member 202.

In an exemplary embodiment, the anisotropy ratio AR for the first andsecond expandable tubular members is defined by the following equation:AR=ln(WT_(f)/WT_(o))/ln(D _(f) /D _(o));  (1)

where AR=anisotropy ratio;

where WT_(f)=final wall thickness of the expandable tubular memberfollowing the radial expansion and plastic deformation of the expandabletubular member;

where WT_(i)=initial wall thickness of the expandable tubular memberprior to the radial expansion and plastic deformation of the expandabletubular member;

where D_(f)=final inside diameter of the expandable tubular memberfollowing the radial expansion and plastic deformation of the expandabletubular member; and

where D_(i)=initial inside diameter of the expandable tubular memberprior to the radial expansion and plastic deformation of the expandabletubular member.

In an exemplary embodiment, the anisotropy ratio AR for the first and/orsecond expandable tubular members, 204 and 204, is greater than 1.

In an exemplary experimental embodiment, the second expandable tubularmember 204 had an anisotropy ratio AR greater than 1, and the radialexpansion and plastic deformation of the second expandable tubularmember did not result in any of the openings, 204 a, 204 b, 204 c, and204 d, splitting or otherwise fracturing the remaining portions of thesecond expandable tubular member. This was an unexpected result.

Referring to FIG. 18, in an exemplary embodiment, one or more of theexpandable tubular members, 12, 14, 24, 26, 102, 104, 106, 108, 202and/or 204 are processed using a method 300 in which a tubular member inan initial state is thermo-mechanically processed in step 302. In anexemplary embodiment, the thermo-mechanical processing 302 includes oneor more heat treating and/or mechanical forming processes. As a result,of the thermo-mechanical processing 302, the tubular member istransformed to an intermediate state. The tubular member is then furtherthermo-mechanically processed in step 304. In an exemplary embodiment,the thermo-mechanical processing 304 includes one or more heat treatingand/or mechanical forming processes. As a result, of thethermo-mechanical processing 304, the tubular member is transformed to afinal state.

In an exemplary embodiment, as illustrated in FIG. 19, during theoperation of the method 300, the tubular member has a ductility D_(PE)and a yield strength YS_(PE) prior to the final thermo-mechanicalprocessing in step 304, and a ductility D_(AE) and a yield strengthYS_(AE) after final thermo-mechanical processing. In an exemplaryembodiment, D_(PE) is greater than D_(AE), and YS_(AE) is greater thanYS_(PE). In this manner, the amount of energy and/or power required totransform the tubular member, using mechanical forming processes, duringthe final thermo-mechanical processing in step 304 is reduced.Furthermore, in this manner, because the YS_(AE) is greater thanYS_(PE), the collapse strength of the tubular member is increased afterthe final thermo-mechanical processing in step 304.

In an exemplary embodiment, one or more of the expandable tubularmembers, 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204, have thefollowing characteristics: Characteristic Value Tensile Strength 60 to120 ksi Yield Strength 50 to 100 ksi Y/T Ratio Maximum of 50/85%Elongation During Radial Expansion Minimum of 35% and PlasticDeformation Width Reduction During Radial Expansion Minimum of 40% andPlastic Deformation Wall Thickness Reduction During Radial Minimum of30% Expansion and Plastic Deformation Anisotropy Minimum of 1.5 MinimumAbsorbed Energy at −4 F. (−20 C.) in 80 ft-lb the Longitudinal DirectionMinimum Absorbed Energy at −4 F. (−20 C.) in 60 ft-lb the TransverseDirection Minimum Absorbed Energy at −4 F. (−20 C.) 60 ft-lb TransverseTo A Weld Area Flare Expansion Testing Minimum of 75% Without A FailureIncrease in Yield Strength Due To Radial Greater than 5.4% Expansion andPlastic Deformation

In an exemplary embodiment, one or more of the expandable tubularmembers, 12, 14, 24, 26, 102, 104, 108, 202 and/or 204, arecharacterized by an expandability coefficient f:i. f=r×n  (2)

-   -   ii. where        -   f=expandability coefficient;        -   1. r=anisotrophy coefficient; and        -   2. n=strain hardening exponent.

In an exemplary embodiment, the anisotropy coefficient for one or moreof the expandable tubular members, 12, 14, 24, 26, 102, 104, 106, 108,202 and/or 204 is greater than 1. In an exemplary embodiment, the strainhardening exponent for one or more of the expandable tubular members,12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204 is greater than 0.12.In an exemplary embodiment, the expandability coefficient for one ormore of the expandable tubular members, 12, 14, 24, 26, 102, 104, 106,108, 202 and/or 204 is greater than 0.12.

In an exemplary embodiment, a tubular member having a higherexpandability coefficient requires less power and/or energy to radiallyexpand and plastically deform each unit length than a tubular memberhaving a lower expandability coefficient. In an exemplary embodiment, atubular member having a higher expandability coefficient requires lesspower and/or energy per unit length to radially expand and plasticallydeform than a tubular member having a lower expandability coefficient.

In several exemplary experimental embodiments, one or more of theexpandable tubular members, 12, 14, 24, 26, 102, 104, 106, 108, 202and/or 204, are steel alloys having one of the following compositions:Steel Element and Percentage By Weight Alloy C Mn P S Si Cu Ni Cr A0.065 1.44 0.01 0.002 0.24 0.01 0.01 0.02 B 0.18 1.28 0.017 0.004 0.290.01 0.01 0.03 C 0.08 0.82 0.006 0.003 0.30 0.16 0.05 0.05 D 0.02 1.310.02 0.001 0.45 — 9.1 18.7

In exemplary experimental embodiment, as illustrated in FIG. 20, asample of an expandable tubular member composed of Alloy A exhibited ayield point before radial expansion and plastic deformation YP_(BE), ayield point after radial expansion and plastic deformation of about 16%YP_(AE16%), and a yield point after radial expansion and plasticdeformation of about 24% YP_(AE24%). In an exemplary experimentalembodiment, YP_(AE24%)>YP_(AE16%)>YP_(BE). Furthermore, in an exemplaryexperimental embodiment, the ductility of the sample of the expandabletubular member composed of Alloy A also exhibited a higher ductilityprior to radial expansion and plastic deformation than after radialexpansion and plastic deformation. These were unexpected results.

In an exemplary experimental embodiment, a sample of an expandabletubular member composed of Alloy A exhibited the following tensilecharacteristics before and after radial expansion and plasticdeformation: Yield Wall Point Yield Elongation Width Thickness ksi Ratio% Reduction % Reduction % Anisotropy Before 46.9 0.69 53 −52 55 0.93Radial Expansion and Plastic Deformation After 16% 65.9 0.83 17 42 510.78 Radial Expansion After 24% 68.5 0.83 5 44 54 0.76 Radial Expansion% Increase 40% for 16% radial expansion 46% for 24% radial expansion

In exemplary experimental embodiment, as illustrated in FIG. 21, asample of an expandable tubular member composed of Alloy B exhibited ayield point before radial expansion and plastic deformation YP_(BE), ayield point after radial expansion and plastic deformation of about 16%YP_(AE16%), and a yield point after radial expansion and plasticdeformation of about 24% YP_(AE24%). In an exemplary embodiment,YP_(AE24%)>YP_(AE16%)>YP_(BE). Furthermore, in an exemplary experimentalembodiment, the ductility of the sample of the expandable tubular membercomposed of Alloy B also exhibited a higher ductility prior to radialexpansion and plastic deformation than after radial expansion andplastic deformation. These were unexpected results.

In an exemplary experimental embodiment, a sample of an expandabletubular member composed of Alloy B exhibited the following tensilecharacteristics before and after radial expansion and plasticdeformation: Yield Wall Point Yield Elongation Width Thickness ksi Ratio% Reduction % Reduction % Anisotropy Before 57.8 0.71 44 43 46 0.93Radial Expansion and Plastic Deformation After 16% 74.4 0.84 16 38 420.87 Radial Expansion After 24% 79.8 0.86 20 36 42 0.81 Radial Expansion% Increase 28.7% increase for 16% radial expansion 38% increase for 24%radial expansion

In an exemplary experimental embodiment, samples of expandable tubularscomposed of Alloys A, B, C, and D exhibited the following tensilecharacteristics prior to radial expansion and plastic deformation:Absorbed Steel Yield Yield Elongation Ani- Energy Expandability Alloyksi Ratio % sotropy ft-lb Coefficient A 47.6 0.71 44 1.48 145 B 57.80.71 44 1.04 62.2 C 61.7 0.80 39 1.92 268 D 48 0.55 56 1.34 —

In an exemplary embodiment, one or more of the expandable tubularmembers, 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204 have astrain hardening exponent greater than 0.12, and a yield ratio is lessthan 0.85.

In an exemplary embodiment, the carbon equivalent C_(e), for tubularmembers having a carbon content (by weight percentage) less than orequal to 0.12%, is given by the following expression:C_(e)═C+Mn/6+(Cr+Mo+V+Ti+Nb)/5+(Ni+Cu)/15  (3)

where

C_(e)=carbon equivalent value;

a. C=carbon percentage by weight;

b. Mn=manganese percentage by weight;

c. Cr=chromium percentage by weight;

d. Mo=molybdenum percentage by weight;

e. V=vanadium percentage by weight;

f. Ti=titanium percentage by weight;

g. Nb=niobium percentage by weight;

h. Ni=nickel percentage by weight; and

i. Cu=copper percentage by weight.

In an exemplary embodiment, the carbon equivalent value C_(e), fortubular members having a carbon content less than or equal to 0.12% (byweight), for one or more of the expandable tubular members, 12, 14, 24,26, 102, 104, 106, 108, 202 and/or 204 is less than 0.21.

In an exemplary embodiment, the carbon equivalent C_(e), for tubularmembers having more than 0.12% carbon content (by weight), is given bythe following expression:C_(e)=C+Si/30+(Mn+Cu+Cr)/20+Ni/60+Mo/15+V/10+5*B  (4)

-   -   where

C_(e)=carbon equivalent value;

a. C=carbon percentage by weight;

b. Si=silicon percentage by weight;

c. Mn=manganese percentage by weight;

d. Cu=copper percentage by weight;

e. Cr=chromium percentage by weight;

f. Ni=nickel percentage by weight;

g. Mo=molybdenum percentage by weight;

h. V=vanadium percentage by weight; and

i. B=boron percentage by weight.

In an exemplary embodiment, the carbon equivalent value C_(e), fortubular members having greater than 0.12% carbon content (by weight),for one or more of the expandable tubular members, 12, 14, 24, 26, 102,104, 106, 108, 202 and/or 204 is less than 0.36.

Referring to FIG. 22 in an exemplary embodiment, a first tubular member2210 includes an internally threaded connection 2212 at an end portion2214. A first end of a tubular sleeve 2216 that includes an internalflange 2218 having a tapered portion 2220, and a second end thatincludes a tapered portion 2222, is then mounted upon and receives theend portion 2214 of the first tubular member 2210. In an exemplaryembodiment, the end portion 2214 of the first tubular member 2210 abutsone side of the internal flange 2218 of the tubular sleeve 2216, and theinternal diameter of the internal flange 2218 of the tubular sleeve 2216is substantially equal to or greater than the maximum internal diameterof the internally threaded connection 2212 of the end portion 2214 ofthe first tubular member 2210. An externally threaded connection 2224 ofan end portion 2226 of a second tubular member 2228 having an annularrecess 2230 is then positioned within the tubular sleeve 2216 andthreadably coupled to the internally threaded connection 2212 of the endportion 2214 of the first tubular member 2210. In an exemplaryembodiment, the internal flange 2218 of the tubular sleeve 2216 mateswith and is received within the annular recess 2230 of the end portion2226 of the second tubular member 2228. Thus, the tubular sleeve 2216 iscoupled to and surrounds the external surfaces of the first and secondtubular members, 2210 and 2228.

The internally threaded connection 2212 of the end portion 2214 of thefirst tubular member 2210 is a box connection, and the externallythreaded connection 2224 of the end portion 2226 of the second tubularmember 2228 is a pin connection. In an exemplary embodiment, theinternal diameter of the tubular sleeve 2216 is at least approximately0.020″ greater than the outside diameters of the first and secondtubular members, 2210 and 2228. In this manner, during the threadedcoupling of the first and second tubular members, 2210 and 2228, fluidicmaterials within the first and second tubular members may be vented fromthe tubular members.

As illustrated in FIG. 22, the first and second tubular members, 2210and 2228, and the tubular sleeve 2216 may be positioned within anotherstructure 2232 such as, for example, a cased or uncased wellbore, andradially expanded and plastically deformed, for example, by displacingand/or rotating a conventional expansion device 2234 within and/orthrough the interiors of the first and second tubular members. Thetapered portions, 2220 and 2222, of the tubular sleeve 2216 facilitatethe insertion and movement of the first and second tubular memberswithin and through the structure 2232, and the movement of the expansiondevice 2234 through the interiors of the first and second tubularmembers, 2210 and 2228, may be, for example, from top to bottom or frombottom to top.

During the radial expansion and plastic deformation of the first andsecond tubular members, 2210 and 2228, the tubular sleeve 2216 is alsoradially expanded and plastically deformed. As a result, the tubularsleeve 2216 may be maintained in circumferential tension and the endportions, 2214 and 2226, of the first and second tubular members, 2210and 2228, may be maintained in circumferential compression.

Sleeve 2216 increases the axial compression loading of the connectionbetween tubular members 2210 and 2228 before and after expansion by theexpansion device 2234. Sleeve 2216 may, for example, be secured totubular members 2210 and 2228 by a heat shrink fit.

In several alternative embodiments, the first and second tubularmembers, 2210 and 2228, are radially expanded and plastically deformedusing other conventional methods for radially expanding and plasticallydeforming tubular members such as, for example, internal pressurization,hydroforming, and/or roller expansion devices and/or any one orcombination of the conventional commercially available expansionproducts and services available from Baker Hughes, WeatherfordInternational, and/or Enventure Global Technology L.L.C.

The use of the tubular sleeve 2216 during (a) the coupling of the firsttubular member 2210 to the second tubular member 2228, (b) the placementof the first and second tubular members in the structure 2232, and (c)the radial expansion and plastic deformation of the first and secondtubular members provides a number of significant benefits. For example,the tubular sleeve 2216 protects the exterior surfaces of the endportions, 2214 and 2226, of the first and second tubular members, 2210and 2228, during handling and insertion of the tubular members withinthe structure 2232. In this manner, damage to the exterior surfaces ofthe end portions, 2214 and 2226, of the first and second tubularmembers, 2210 and 2228, is avoided that could otherwise result in stressconcentrations that could cause a catastrophic failure during subsequentradial expansion operations. Furthermore, the tubular sleeve 2216provides an alignment guide that facilitates the insertion and threadedcoupling of the second tubular member 2228 to the first tubular member2210. In this manner, misalignment that could result in damage to thethreaded connections, 2212 and 2224, of the first and second tubularmembers, 2210 and 2228, may be avoided. In addition, during the relativerotation of the second tubular member with respect to the first tubularmember, required during the threaded coupling of the first and secondtubular members, the tubular sleeve 2216 provides an indication of towhat degree the first and second tubular members are threadably coupled.For example, if the tubular sleeve 2216 can be easily rotated, thatwould indicate that the first and second tubular members, 2210 and 2228,are not fully threadably coupled and in intimate contact with theinternal flange 2218 of the tubular sleeve. Furthermore, the tubularsleeve 2216 may prevent crack propagation during the radial expansionand plastic deformation of the first and second tubular members, 2210and 2228. In this manner, failure modes such as, for example,longitudinal cracks in the end portions, 2214 and 2226, of the first andsecond tubular members may be limited in severity or eliminated alltogether. In addition, after completing the radial expansion and plasticdeformation of the first and second tubular members, 2210 and 2228, thetubular sleeve 2216 may provide a fluid tight metal-to-metal sealbetween interior surface of the tubular sleeve 2216 and the exteriorsurfaces of the end portions, 2214 and 2226, of the first and secondtubular members. In this manner, fluidic materials are prevented frompassing through the threaded connections, 2212 and 2224, of the firstand second tubular members, 2210 and 2228, into the annulus between thefirst and second tubular members and the structure 2232. Furthermore,because, following the radial expansion and plastic deformation of thefirst and second tubular members, 2210 and 2228, the tubular sleeve 2216may be maintained in circumferential tension and the end portions, 2214and 2226, of the first and second tubular members, 2210 and 2228, may bemaintained in circumferential compression, axial loads and/or torqueloads may be transmitted through the tubular sleeve.

In several exemplary embodiments, one or more portions of the first andsecond tubular members, 2210 and 2228, and the tubular sleeve 2216 haveone or more of the material properties of one or more of the tubularmembers 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204.

Referring to FIG. 23, in an exemplary embodiment, a first tubular member210 includes an internally threaded connection 2312 at an end portion2314. A first end of a tubular sleeve 2316 includes an internal flange2318 and a tapered portion 2320. A second end of the sleeve 2316includes an internal flange 2321 and a tapered portion 2322. Anexternally threaded connection 2324 of an end portion 2326 of a secondtubular member 2328 having an annular recess 2330, is then positionedwithin the tubular sleeve 2316 and threadably coupled to the internallythreaded connection 2312 of the end portion 2314 of the first tubularmember 2310. The internal flange 2318 of the sleeve 2316 mates with andis received within the annular recess 2330.

The first tubular member 2310 includes a recess 2331. The internalflange 2321 mates with and is received within the annular recess 2331.Thus, the sleeve 2316 is coupled to and surrounds the external surfacesof the first and second tubular members 2310 and 2328.

The internally threaded connection 2312 of the end portion 2314 of thefirst tubular member 2310 is a box connection, and the externallythreaded connection 2324 of the end portion 2326 of the second tubularmember 2328 is a pin connection. In an exemplary embodiment, theinternal diameter of the tubular sleeve 2316 is at least approximately0.020″ greater than the outside diameters of the first and secondtubular members 2310 and 2328. In this manner, during the threadedcoupling of the first and second tubular members 2310 and 2328, fluidicmaterials within the first and second tubular members may be vented fromthe tubular members.

As illustrated in FIG. 23, the first and second tubular members 2310 and2328, and the tubular sleeve 2316 may then be positioned within anotherstructure 2332 such as, for example, a wellbore, and radially expandedand plastically deformed, for example, by displacing and/or rotating anexpansion device 2334 through and/or within the interiors of the firstand second tubular members. The tapered portions 2320 and 2322, of thetubular sleeve 2316 facilitates the insertion and movement of the firstand second tubular members within and through the structure 2332, andthe displacement of the expansion device 2334 through the interiors ofthe first and second tubular members 2310 and 2328, may be from top tobottom or from bottom to top.

During the radial expansion and plastic deformation of the first andsecond tubular members 2310 and 2328, the tubular sleeve 2316 is alsoradially expanded and plastically deformed. In an exemplary embodiment,as a result, the tubular sleeve 2316 may be maintained incircumferential tension and the end portions 2314 and 2326, of the firstand second tubular members 2310 and 2328, may be maintained incircumferential compression.

Sleeve 2316 increases the axial tension loading of the connectionbetween tubular members 2310 and 2328 before and after expansion by theexpansion device 2334. Sleeve 2316 may be secured to tubular members2310 and 2328 by a heat shrink fit.

In several exemplary embodiments, one or more portions of the first andsecond tubular members, 2310 and 2328, and the tubular sleeve 2316 haveone or more of the material properties of one or more of the tubularmembers 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204.

Referring to FIG. 24, in an exemplary embodiment, a first tubular member2410 includes an internally threaded connection 2412 at an end portion2414. A first end of a tubular sleeve 2416 includes an internal flange2418 and a tapered portion 2420. A second end of the sleeve 2416includes an internal flange 2421 and a tapered portion 2422. Anexternally threaded connection 2424 of an end portion 2426 of a secondtubular member 2428 having an annular recess 2430, is then positionedwithin the tubular sleeve 2416 and threadably coupled to the internallythreaded connection 2412 of the end portion 2414 of the first tubularmember 2410. The internal flange 2418 of the sleeve 2416 mates with andis received within the annular recess 2430. The first tubular member2410 includes a recess 2431. The internal flange 2421 mates with and isreceived within the annular recess 2431. Thus, the sleeve 2416 iscoupled to and surrounds the external surfaces of the first and secondtubular members 2410 and 2428.

The internally threaded connection 2412 of the end portion 2414 of thefirst tubular member 2410 is a box connection, and the externallythreaded connection 2424 of the end portion 2426 of the second tubularmember 2428 is a pin connection. In an exemplary embodiment, theinternal diameter of the tubular sleeve 2416 is at least approximately0.020″ greater than the outside diameters of the first and secondtubular members 2410 and 2428. In this manner, during the threadedcoupling of the first and second tubular members 2410 and 2428, fluidicmaterials within the first and second tubular members may be vented fromthe tubular members.

As illustrated in FIG. 24, the first and second tubular members 2410 and2428, and the tubular sleeve 2416 may then be positioned within anotherstructure 2432 such as, for example, a wellbore, and radially expandedand plastically deformed, for example, by displacing and/or rotating anexpansion device 2434 through and/or within the interiors of the firstand second tubular members. The tapered portions 2420 and 2422, of thetubular sleeve 2416 facilitate the insertion and movement of the firstand second tubular members within and through the structure 2432, andthe displacement of the expansion device 2434 through the interiors ofthe first and second tubular members, 2410 and 2428, may be from top tobottom or from bottom to top.

During the radial expansion and plastic deformation of the first andsecond tubular members, 2410 and 2428, the tubular sleeve 2416 is alsoradially expanded and plastically deformed. In an exemplary embodiment,as a result, the tubular sleeve 2416 may be maintained incircumferential tension and the end portions, 2414 and 2426, of thefirst and second tubular members, 2410 and 2428, may be maintained incircumferential compression.

The sleeve 2416 increases the axial compression and tension loading ofthe connection between tubular members 2410 and 2428 before and afterexpansion by expansion device 2424. Sleeve 2416 may be secured totubular members 2410 and 2428 by a heat shrink fit.

In several exemplary embodiments, one or more portions of the first andsecond tubular members, 2410 and 2428, and the tubular sleeve 2416 haveone or more of the material properties of one or more of the tubularmembers 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204.

Referring to FIG. 25, in an exemplary embodiment, a first tubular member2510 includes an internally threaded connection 2512 at an end portion2514. A first end of a tubular sleeve 2516 includes an internal flange2518 and a relief 2520. A second end of the sleeve 2516 includes aninternal flange 2521 and a relief 2522. An externally threadedconnection 2524 of an end portion 2526 of a second tubular member 2528having an annular recess 2530, is then positioned within the tubularsleeve 2516 and threadably coupled to the internally threaded connection2512 of the end portion 2514 of the first tubular member 2510. Theinternal flange 2518 of the sleeve 2516 mates with and is receivedwithin the annular recess 2530. The first tubular member 2510 includes arecess 2531. The internal flange 2521 mates with and is received withinthe annular recess 2531. Thus, the sleeve 2516 is coupled to andsurrounds the external surfaces of the first and second tubular members2510 and 2528.

The internally threaded connection 2512 of the end portion 2514 of thefirst tubular member 2510 is a box connection, and the externallythreaded connection 2524 of the end portion 2526 of the second tubularmember 2528 is a pin connection. In an exemplary embodiment, theinternal diameter of the tubular sleeve 2516 is at least approximately0.020″ greater than the outside diameters of the first and secondtubular members 2510 and 2528. In this manner, during the threadedcoupling of the first and second tubular members 2510 and 2528, fluidicmaterials within the first and second tubular members may be vented fromthe tubular members.

As illustrated in FIG. 25, the first and second tubular members 2510 and2528, and the tubular sleeve 2516 may then be positioned within anotherstructure 2532 such as, for example, a wellbore, and radially expandedand plastically deformed, for example, by displacing and/or rotating anexpansion device 2534 through and/or within the interiors of the firstand second tubular members. The reliefs 2520 and 2522 are each filledwith a sacrificial material 2540 including a tapered surface 2542 and2544, respectively. The material 2540 may be a metal or a synthetic, andis provided to facilitate the insertion and movement of the first andsecond tubular members 2510 and 2528, through the structure 2532. Thedisplacement of the expansion device 2534 through the interiors of thefirst and second tubular members 2510 and 2528, may, for example, befrom top to bottom or from bottom to top.

During the radial expansion and plastic deformation of the first andsecond tubular members 2510 and 2528, the tubular sleeve 2516 is alsoradially expanded and plastically deformed. In an exemplary embodiment,as a result, the tubular sleeve 2516 may be maintained incircumferential tension and the end portions 2514 and 2526, of the firstand second tubular members, 2510 and 2528, may be maintained incircumferential compression.

The addition of the sacrificial material 2540, provided on sleeve 2516,avoids stress risers on the sleeve 2516 and the tubular member 2510. Thetapered surfaces 2542 and 2544 are intended to wear or even becomedamaged, thus incurring such wear or damage which would otherwise beborne by sleeve 2516. Sleeve 2516 may be secured to tubular members 2510and 2528 by a heat shrink fit.

In several exemplary embodiments, one or more portions of the first andsecond tubular members, 2510 and 2528, and the tubular sleeve 2516 haveone or more of the material properties of one or more of the tubularmembers 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204.

Referring to FIG. 26, in an exemplary embodiment, a first tubular member2610 includes an internally threaded connection 2612 at an end portion2614. A first end of a tubular sleeve 2616 includes an internal flange2618 and a tapered portion 2620. A second end of the sleeve 2616includes an internal flange 2621 and a tapered portion 2622. Anexternally threaded connection 2624 of an end portion 2626 of a secondtubular member 2628 having an annular recess 2630, is then positionedwithin the tubular sleeve 2616 and threadably coupled to the internallythreaded connection 2612 of the end portion 2614 of the first tubularmember 2610. The internal flange 2618 of the sleeve 2616 mates with andis received within the annular recess 2630.

The first tubular member 2610 includes a recess 2631. The internalflange 2621 mates with and is received within the annular recess 2631.Thus, the sleeve 2616 is coupled to and surrounds the external surfacesof the first and second tubular members 2610 and 2628.

The internally threaded connection 2612 of the end portion 2614 of thefirst tubular member 2610 is a box connection, and the externallythreaded connection 2624 of the end portion 2626 of the second tubularmember 2628 is a pin connection. In an exemplary embodiment, theinternal diameter of the tubular sleeve 2616 is at least approximately0.020″ greater than the outside diameters of the first and secondtubular members 2610 and 2628. In this manner, during the threadedcoupling of the first and second tubular members 2610 and 2628, fluidicmaterials within the first and second tubular members may be vented fromthe tubular members.

As illustrated in FIG. 26, the first and second tubular members 2610 and2628, and the tubular sleeve 2616 may then be positioned within anotherstructure 2632 such as, for example, a wellbore, and radially expandedand plastically deformed, for example, by displacing and/or rotating anexpansion device 2634 through and/or within the interiors of the firstand second tubular members. The tapered portions 2620 and 2622, of thetubular sleeve 2616 facilitates the insertion and movement of the firstand second tubular members within and through the structure 2632, andthe displacement of the expansion device 2634 through the interiors ofthe first and second tubular members 2610 and 2628, may, for example, befrom top to bottom or from bottom to top.

During the radial expansion and plastic deformation of the first andsecond tubular members 2610 and 2628, the tubular sleeve 2616 is alsoradially expanded and plastically deformed. In an exemplary embodiment,as a result, the tubular sleeve 2616 may be maintained incircumferential tension and the end portions 2614 and 2626, of the firstand second tubular members 2610 and 2628, may be maintained incircumferential compression.

Sleeve 2616 is covered by a thin walled cylinder of sacrificial material2640. Spaces 2623 and 2624, adjacent tapered portions 2620 and 2622,respectively, are also filled with an excess of the sacrificial material2640. The material may be a metal or a synthetic, and is provided tofacilitate the insertion and movement of the first and second tubularmembers 2610 and 2628, through the structure 2632.

The addition of the sacrificial material 2640, provided on sleeve 2616,avoids stress risers on the sleeve 2616 and the tubular member 2610. Theexcess of the sacrificial material 2640 adjacent tapered portions 2620and 2622 are intended to wear or even become damaged, thus incurringsuch wear or damage which would otherwise be borne by sleeve 2616.Sleeve 2616 may be secured to tubular members 2610 and 2628 by a heatshrink fit.

In several exemplary embodiments, one or more portions of the first andsecond tubular members, 2610 and 2628, and the tubular sleeve 2616 haveone or more of the material properties of one or more of the tubularmembers 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204.

Referring to FIG. 27, in an exemplary embodiment, a first tubular member2710 includes an internally threaded connection 2712 at an end portion2714. A first end of a tubular sleeve 2716 includes an internal flange2718 and a tapered portion 2720. A second end of the sleeve 2716includes an internal flange 2721 and a tapered portion 2722. Anexternally threaded connection 2724 of an end portion 2726 of a secondtubular member 2728 having an annular recess 2730, is then positionedwithin the tubular sleeve 2716 and threadably coupled to the internallythreaded connection 2712 of the end portion 2714 of the first tubularmember 2710. The internal flange 2718 of the sleeve 2716 mates with andis received within the annular recess 2730.

The first tubular member 2710 includes a recess 2731. The internalflange 2721 mates with and is received within the annular recess 2731.Thus, the sleeve 2716 is coupled to and surrounds the external surfacesof the first and second tubular members 2710 and 2728.

The internally threaded connection 2712 of the end portion 2714 of thefirst tubular member 2710 is a box connection, and the externallythreaded connection 2724 of the end portion 2726 of the second tubularmember 2728 is a pin connection. In an exemplary embodiment, theinternal diameter of the tubular sleeve 2716 is at least approximately0.020″ greater than the outside diameters of the first and secondtubular members 2710 and 2728. In this manner, during the threadedcoupling of the first and second tubular members 2710 and 2728, fluidicmaterials within the first and second tubular members may be vented fromthe tubular members.

As illustrated in FIG. 27, the first and second tubular members 2710 and2728, and the tubular sleeve 2716 may then be positioned within anotherstructure 2732 such as, for example, a wellbore, and radially expandedand plastically deformed, for example, by displacing and/or rotating anexpansion device 2734 through and/or within the interiors of the firstand second tubular members. The tapered portions 2720 and 2722, of thetubular sleeve 2716 facilitates the insertion and movement of the firstand second tubular members within and through the structure 2732, andthe displacement of the expansion device 2734 through the interiors ofthe first and second tubular members 2710 and 2728, may be from top tobottom or from bottom to top.

During the radial expansion and plastic deformation of the first andsecond tubular members 2710 and 2728, the tubular sleeve 2716 is alsoradially expanded and plastically deformed. In an exemplary embodiment,as a result, the tubular sleeve 2716 may be maintained incircumferential tension and the end portions 2714 and 2726, of the firstand second tubular members 2710 and 2728, may be maintained incircumferential compression.

Sleeve 2716 has a variable thickness due to one or more reducedthickness portions 2790 and/or increased thickness portions 2792.

Varying the thickness of sleeve 2716 provides the ability to control orinduce stresses at selected positions along the length of sleeve 2716and the end portions 2724 and 2726. Sleeve 2716 may be secured totubular members 2710 and 2728 by a heat shrink fit.

In several exemplary embodiments, one or more portions of the first andsecond tubular members, 2710 and 2728, and the tubular sleeve 2716 haveone or more of the material properties of one or more of the tubularmembers 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204.

Referring to FIG. 28, in an alternative embodiment, instead of varyingthe thickness of sleeve 2716, the same result described above withreference to FIG. 27, may be achieved by adding a member 2740 which maybe coiled onto the grooves 2739 formed in sleeve 2716, thus varying thethickness along the length of sleeve 2716.

Referring to FIG. 29, in an exemplary embodiment, a first tubular member2910 includes an internally threaded connection 2912 and an internalannular recess 2914 at an end portion 2916. A first end of a tubularsleeve 2918 includes an internal flange 2920, and a second end of thesleeve 2916 mates with and receives the end portion 2916 of the firsttubular member 2910. An externally threaded connection 2922 of an endportion 2924 of a second tubular member 2926 having an annular recess2928, is then positioned within the tubular sleeve 2918 and threadablycoupled to the internally threaded connection 2912 of the end portion2916 of the first tubular member 2910. The internal flange 2920 of thesleeve 2918 mates with and is received within the annular recess 2928. Asealing element 2930 is received within the internal annular recess 2914of the end portion 2916 of the first tubular member 2910.

The internally threaded connection 2912 of the end portion 2916 of thefirst tubular member 2910 is a box connection, and the externallythreaded connection 2922 of the end portion 2924 of the second tubularmember 2926 is a pin connection. In an exemplary embodiment, theinternal diameter of the tubular sleeve 2918 is at least approximately0.020″ greater than the outside diameters of the first tubular member2910. In this manner, during the threaded coupling of the first andsecond tubular members 2910 and 2926, fluidic materials within the firstand second tubular members may be vented from the tubular members.

The first and second tubular members 2910 and 2926, and the tubularsleeve 2918 may be positioned within another structure such as, forexample, a wellbore, and radially expanded and plastically deformed, forexample, by displacing and/or rotating an expansion device throughand/or within the interiors of the first and second tubular members.

During the radial expansion and plastic deformation of the first andsecond tubular members 2910 and 2926, the tubular sleeve 2918 is alsoradially expanded and plastically deformed. In an exemplary embodiment,as a result, the tubular sleeve 2918 may be maintained incircumferential tension and the end portions 2916 and 2924, of the firstand second tubular members 2910 and 2926, respectively, may bemaintained in circumferential compression.

In an exemplary embodiment, before, during, and after the radialexpansion and plastic deformation of the first and second tubularmembers 2910 and 2926, and the tubular sleeve 2918, the sealing element2930 seals the interface between the first and second tubular members.In an exemplary embodiment, during and after the radial expansion andplastic deformation of the first and second tubular members 2910 and2926, and the tubular sleeve 2918, a metal to metal seal is formedbetween at least one of: the first and second tubular members 2910 and2926, the first tubular member and the tubular sleeve 2918, and/or thesecond tubular member and the tubular sleeve. In an exemplaryembodiment, the metal to metal seal is both fluid tight and gas tight.

In several exemplary embodiments, one or more portions of the first andsecond tubular members, 2910 and 2926, the tubular sleeve 2918, and thesealing element 2930 have one or more of the material properties of oneor more of the tubular members 12, 14, 24, 26, 102, 104, 106, 108, 202and/or 204.

Referring to FIG. 30 a, in an exemplary embodiment, a first tubularmember 3010 includes internally threaded connections 3012 a and 3012 b,spaced apart by a cylindrical internal surface 3014, at an end portion3016. Externally threaded connections 3018 a and 3018 b, spaced apart bya cylindrical external surface 3020, of an end portion 3022 of a secondtubular member 3024 are threadably coupled to the internally threadedconnections, 3012 a and 3012 b, respectively, of the end portion 3016 ofthe first tubular member 3010. A sealing element 3026 is received withinan annulus defined between the internal cylindrical surface 3014 of thefirst tubular member 3010 and the external cylindrical surface 3020 ofthe second tubular member 3024.

The internally threaded connections, 3012 a and 3012 b, of the endportion 3016 of the first tubular member 3010 are box connections, andthe externally threaded connections, 3018 a and 3018 b, of the endportion 3022 of the second tubular member 3024 are pin connections. Inan exemplary embodiment, the sealing element 3026 is an elastomericand/or metallic sealing element.

The first and second tubular members 3010 and 3024 may be positionedwithin another structure such as, for example, a wellbore, and radiallyexpanded and plastically deformed, for example, by displacing and/orrotating an expansion device through and/or within the interiors of thefirst and second tubular members.

In an exemplary embodiment, before, during, and after the radialexpansion and plastic deformation of the first and second tubularmembers 3010 and 3024, the sealing element 3026 seals the interfacebetween the first and second tubular members. In an exemplaryembodiment, before, during and/or after the radial expansion and plasticdeformation of the first and second tubular members 3010 and 3024, ametal to metal seal is formed between at least one of: the first andsecond tubular members 3010 and 3024, the first tubular member and thesealing element 3026, and/or the second tubular member and the sealingelement. In an exemplary embodiment, the metal to metal seal is bothfluid tight and gas tight.

In an alternative embodiment, the sealing element 3026 is omitted, andduring and/or after the radial expansion and plastic deformation of thefirst and second tubular members 3010 and 3024, a metal to metal seal isformed between the first and second tubular members.

In several exemplary embodiments, one or more portions of the first andsecond tubular members, 3010 and 3024, the sealing element 3026 have oneor more of the material properties of one or more of the tubular members12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204.

Referring to FIG. 30 b, in an exemplary embodiment, a first tubularmember 3030 includes internally threaded connections 3032 a and 3032 b,spaced apart by an undulating approximately cylindrical internal surface3034, at an end portion 3036. Externally threaded connections 3038 a and3038 b, spaced apart by a cylindrical external surface 3040, of an endportion 3042 of a second tubular member 3044 are threadably coupled tothe internally threaded connections, 3032 a and 3032 b, respectively, ofthe end portion 3036 of the first tubular member 3030. A sealing element3046 is received within an annulus defined between the undulatingapproximately cylindrical internal surface 3034 of the first tubularmember 3030 and the external cylindrical surface 3040 of the secondtubular member 3044.

The internally threaded connections, 3032 a and 3032 b, of the endportion 3036 of the first tubular member 3030 are box connections, andthe externally threaded connections, 3038 a and 3038 b, of the endportion 3042 of the second tubular member 3044 are pin connections. Inan exemplary embodiment, the sealing element 3046 is an elastomericand/or metallic sealing element.

The first and second tubular members 3030 and 3044 may be positionedwithin another structure such as, for example, a wellbore, and radiallyexpanded and plastically deformed, for example, by displacing and/orrotating an expansion device through and/or within the interiors of thefirst and second tubular members.

In an exemplary embodiment, before, during, and after the radialexpansion and plastic deformation of the first and second tubularmembers 3030 and 3044, the sealing element 3046 seals the interfacebetween the first and second tubular members. In an exemplaryembodiment, before, during and/or after the radial expansion and plasticdeformation of the first and second tubular members 3030 and 3044, ametal to metal seal is formed between at least one of: the first andsecond tubular members 3030 and 3044, the first tubular member and thesealing element 3046, and/or the second tubular member and the sealingelement. In an exemplary embodiment, the metal to metal seal is bothfluid tight and gas tight.

In an alternative embodiment, the sealing element 3046 is omitted, andduring and/or after the radial expansion and plastic deformation of thefirst and second tubular members 3030 and 3044, a metal to metal seal isformed between the first and second tubular members.

In several exemplary embodiments, one or more portions of the first andsecond tubular members, 3030 and 3044, the sealing element 3046 have oneor more of the material properties of one or more of the tubular members12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204.

Referring to FIG. 30 c, in an exemplary embodiment, a first tubularmember 3050 includes internally threaded connections 3052 a and 3052 b,spaced apart by a cylindrical internal surface 3054 including one ormore square grooves 3056, at an end portion 3058. Externally threadedconnections 3060 a and 3060 b, spaced apart by a cylindrical externalsurface 3062 including one or more square grooves 3064, of an endportion 3066 of a second tubular member 3068 are threadably coupled tothe internally threaded connections, 3052 a and 3052 b, respectively, ofthe end portion 3058 of the first tubular member 3050. A sealing element3070 is received within an annulus defined between the cylindricalinternal surface 3054 of the first tubular member 3050 and the externalcylindrical surface 3062 of the second tubular member 3068.

The internally threaded connections, 3052 a and 3052 b, of the endportion 3058 of the first tubular member 3050 are box connections, andthe externally threaded connections, 3060 a and 3060 b, of the endportion 3066 of the second tubular member 3068 are pin connections. Inan exemplary embodiment, the sealing element 3070 is an elastomericand/or metallic sealing element.

The first and second tubular members 3050 and 3068 may be positionedwithin another structure such as, for example, a wellbore, and radiallyexpanded and plastically deformed, for example, by displacing and/orrotating an expansion device through and/or within the interiors of thefirst and second tubular members.

In an exemplary embodiment, before, during, and after the radialexpansion and plastic deformation of the first and second tubularmembers 3050 and 3068, the sealing element 3070 seals the interfacebetween the first and second tubular members. In an exemplaryembodiment, before, during and/or after the radial expansion and plasticdeformation of the first and second tubular members, 3050 and 3068, ametal to metal seal is formed between at least one of: the first andsecond tubular members, the first tubular member and the sealing element3070, and/or the second tubular member and the sealing element. In anexemplary embodiment, the metal to metal seal is both fluid tight andgas tight.

In an alternative embodiment, the sealing element 3070 is omitted, andduring and/or after the radial expansion and plastic deformation of thefirst and second tubular members 950 and 968, a metal to metal seal isformed between the first and second tubular members.

In several exemplary embodiments, one or more portions of the first andsecond tubular members, 3050 and 3068, the sealing element 3070 have oneor more of the material properties of one or more of the tubular members12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204.

Referring to FIG. 31, in an exemplary embodiment, a first tubular member3110 includes internally threaded connections, 3112 a and 3112 b, spacedapart by a non-threaded internal surface 3114, at an end portion 3116.Externally threaded connections, 3118 a and 3118 b, spaced apart by anon-threaded external surface 3120, of an end portion 3122 of a secondtubular member 3124 are threadably coupled to the internally threadedconnections, 3112 a and 3112 b, respectively, of the end portion 3122 ofthe first tubular member 3124.

First, second, and/or third tubular sleeves, 3126, 3128, and 3130, arecoupled the external surface of the first tubular member 3110 inopposing relation to the threaded connection formed by the internal andexternal threads, 3112 a and 3118 a, the interface between thenon-threaded surfaces, 3114 and 3120, and the threaded connection formedby the internal and external threads, 3112 b and 3118 b, respectively.

The internally threaded connections, 3112 a and 3112 b, of the endportion 3116 of the first tubular member 3110 are box connections, andthe externally threaded connections, 3118 a and 3118 b, of the endportion 3122 of the second tubular member 3124 are pin connections.

The first and second tubular members 3110 and 3124, and the tubularsleeves 3126, 3128, and/or 3130, may then be positioned within anotherstructure 3132 such as, for example, a wellbore, and radially expandedand plastically deformed, for example, by displacing and/or rotating anexpansion device 3134 through and/or within the interiors of the firstand second tubular members.

During the radial expansion and plastic deformation of the first andsecond tubular members 3110 and 3124, the tubular sleeves 3126, 3128and/or 3130 are also radially expanded and plastically deformed. In anexemplary embodiment, as a result, the tubular sleeves 3126, 3128,and/or 3130 are maintained in circumferential tension and the endportions 3116 and 3122, of the first and second tubular members 3110 and3124, may be maintained in circumferential compression.

The sleeves 3126, 3128, and/or 3130 may, for example, be secured to thefirst tubular member 3110 by a heat shrink fit.

In several exemplary embodiments, one or more portions of the first andsecond tubular members, 3110 and 3124, and the sleeves, 3126, 3128, and3130, have one or more of the material properties of one or more of thetubular members 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204.

Referring to FIG. 32 a, in an exemplary embodiment, a first tubularmember 3210 includes an internally threaded connection 3212 at an endportion 3214. An externally threaded connection 3216 of an end portion3218 of a second tubular member 3220 are threadably coupled to theinternally threaded connection 3212 of the end portion 3214 of the firsttubular member 3210.

The internally threaded connection 3212 of the end portion 3214 of thefirst tubular member 3210 is a box connection, and the externallythreaded connection 3216 of the end portion 3218 of the second tubularmember 3220 is a pin connection.

A tubular sleeve 3222 including internal flanges 3224 and 3226 ispositioned proximate and surrounding the end portion 3214 of the firsttubular member 3210. As illustrated in FIG. 32 b, the tubular sleeve3222 is then forced into engagement with the external surface of the endportion 3214 of the first tubular member 3210 in a conventional manner.As a result, the end portions, 3214 and 3218, of the first and secondtubular members, 3210 and 3220, are upset in an undulating fashion.

The first and second tubular members 3210 and 3220, and the tubularsleeve 3222, may then be positioned within another structure such as,for example, a wellbore, and radially expanded and plastically deformed,for example, by displacing and/or rotating an expansion device throughand/or within the interiors of the first and second tubular members.

During the radial expansion and plastic deformation of the first andsecond tubular members 3210 and 3220, the tubular sleeve 3222 is alsoradially expanded and plastically deformed. In an exemplary embodiment,as a result, the tubular sleeve 3222 is maintained in circumferentialtension and the end portions 3214 and 3218, of the first and secondtubular members 3210 and 3220, may be maintained in circumferentialcompression.

In several exemplary embodiments, one or more portions of the first andsecond tubular members, 3210 and 3220, and the sleeve 3222 have one ormore of the material properties of one or more of the tubular members12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204.

Referring to FIG. 33, in an exemplary embodiment, a first tubular member3310 includes an internally threaded connection 3312 and an annularprojection 3314 at an end portion 3316.

A first end of a tubular sleeve 3318 that includes an internal flange3320 having a tapered portion 3322 and an annular recess 3324 forreceiving the annular projection 3314 of the first tubular member 3310,and a second end that includes a tapered portion 3326, is then mountedupon and receives the end portion 3316 of the first tubular member 3310.

In an exemplary embodiment, the end portion 3316 of the first tubularmember 3310 abuts one side of the internal flange 3320 of the tubularsleeve 3318 and the annular projection 3314 of the end portion of thefirst tubular member mates with and is received within the annularrecess 3324 of the internal flange of the tubular sleeve, and theinternal diameter of the internal flange 3320 of the tubular sleeve 3318is substantially equal to or greater than the maximum internal diameterof the internally threaded connection 3312 of the end portion 3316 ofthe first tubular member 3310. An externally threaded connection 3326 ofan end portion 3328 of a second tubular member 3330 having an annularrecess 3332 is then positioned within the tubular sleeve 3318 andthreadably coupled to the internally threaded connection 3312 of the endportion 3316 of the first tubular member 3310. In an exemplaryembodiment, the internal flange 3332 of the tubular sleeve 3318 mateswith and is received within the annular recess 3332 of the end portion3328 of the second tubular member 3330. Thus, the tubular sleeve 3318 iscoupled to and surrounds the external surfaces of the first and secondtubular members, 3310 and 3328.

The internally threaded connection 3312 of the end portion 3316 of thefirst tubular member 3310 is a box connection, and the externallythreaded connection 3326 of the end portion 3328 of the second tubularmember 3330 is a pin connection. In an exemplary embodiment, theinternal diameter of the tubular sleeve 3318 is at least approximately0.020″ greater than the outside diameters of the first and secondtubular members, 3310 and 3330. In this manner, during the threadedcoupling of the first and second tubular members, 3310 and 3330, fluidicmaterials within the first and second tubular members may be vented fromthe tubular members.

As illustrated in FIG. 33, the first and second tubular members, 3310and 3330, and the tubular sleeve 3318 may be positioned within anotherstructure 3334 such as, for example, a cased or uncased wellbore, andradially expanded and plastically deformed, for example, by displacingand/or rotating a conventional expansion device 3336 within and/orthrough the interiors of the first and second tubular members. Thetapered portions, 3322 and 3326, of the tubular sleeve 3318 facilitatethe insertion and movement of the first and second tubular memberswithin and through the structure 3334, and the movement of the expansiondevice 3336 through the interiors of the first and second tubularmembers, 3310 and 3330, may, for example, be from top to bottom or frombottom to top.

During the radial expansion and plastic deformation of the first andsecond tubular members, 3310 and 3330, the tubular sleeve 3318 is alsoradially expanded and plastically deformed. As a result, the tubularsleeve 3318 may be maintained in circumferential tension and the endportions, 3316 and 3328, of the first and second tubular members, 3310and 3330, may be maintained in circumferential compression.

Sleeve 3316 increases the axial compression loading of the connectionbetween tubular members 3310 and 3330 before and after expansion by theexpansion device 3336. Sleeve 3316 may be secured to tubular members3310 and 3330, for example, by a heat shrink fit.

In several alternative embodiments, the first and second tubularmembers, 3310 and 3330, are radially expanded and plastically deformedusing other conventional methods for radially expanding and plasticallydeforming tubular members such as, for example, internal pressurization,hydroforming, and/or roller expansion devices and/or any one orcombination of the conventional commercially available expansionproducts and services available from Baker Hughes, WeatherfordInternational, and/or Enventure Global Technology L.L.C.

The use of the tubular sleeve 3318 during (a) the coupling of the firsttubular member 3310 to the second tubular member 3330, (b) the placementof the first and second tubular members in the structure 3334, and (c)the radial expansion and plastic deformation of the first and secondtubular members provides a number of significant benefits. For example,the tubular sleeve 3318 protects the exterior surfaces of the endportions, 3316 and 3328, of the first and second tubular members, 3310and 3330, during handling and insertion of the tubular members withinthe structure 3334. In this manner, damage to the exterior surfaces ofthe end portions, 3316 and 3328, of the first and second tubularmembers, 3310 and 3330, is avoided that could otherwise result in stressconcentrations that could cause a catastrophic failure during subsequentradial expansion operations. Furthermore, the tubular sleeve 3318provides an alignment guide that facilitates the insertion and threadedcoupling of the second tubular member 3330 to the first tubular member3310. In this manner, misalignment that could result in damage to thethreaded connections, 3312 and 3326, of the first and second tubularmembers, 3310 and 3330, may be avoided. In addition, during the relativerotation of the second tubular member with respect to the first tubularmember, required during the threaded coupling of the first and secondtubular members, the tubular sleeve 3318 provides an indication of towhat degree the first and second tubular members are threadably coupled.For example, if the tubular sleeve 3318 can be easily rotated, thatwould indicate that the first and second tubular members, 3310 and 3330,are not fully threadably coupled and in intimate contact with theinternal flange 3320 of the tubular sleeve. Furthermore, the tubularsleeve 3318 may prevent crack propagation during the radial expansionand plastic deformation of the first and second tubular members, 3310and 3330. In this manner, failure modes such as, for example,longitudinal cracks in the end portions, 3316 and 3328, of the first andsecond tubular members may be limited in severity or eliminated alltogether. In addition, after completing the radial expansion and plasticdeformation of the first and second tubular members, 3310 and 3330, thetubular sleeve 3318 may provide a fluid tight metal-to-metal sealbetween interior surface of the tubular sleeve 3318 and the exteriorsurfaces of the end portions, 3316 and 3328, of the first and secondtubular members. In this manner, fluidic materials are prevented frompassing through the threaded connections, 3312 and 3326, of the firstand second tubular members, 3310 and 3330, into the annulus between thefirst and second tubular members and the structure 3334. Furthermore,because, following the radial expansion and plastic deformation of thefirst and second tubular members, 3310 and 3330, the tubular sleeve 3318may be maintained in circumferential tension and the end portions, 3316and 3328, of the first and second tubular members, 3310 and 3330, may bemaintained in circumferential compression, axial loads and/or torqueloads may be transmitted through the tubular sleeve.

In several exemplary embodiments, one or more portions of the first andsecond tubular members, 3310 and 3330, and the sleeve 3318 have one ormore of the material properties of one or more of the tubular members12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204.

Referring to FIGS. 34 a, 34 b, and 34 c, in an exemplary embodiment, afirst tubular member 3410 includes an internally threaded connection1312 and one or more external grooves 3414 at an end portion 3416.

A first end of a tubular sleeve 3418 that includes an internal flange3420 and a tapered portion 3422, a second end that includes a taperedportion 3424, and an intermediate portion that includes one or morelongitudinally aligned openings 3426, is then mounted upon and receivesthe end portion 3416 of the first tubular member 3410.

In an exemplary embodiment, the end portion 3416 of the first tubularmember 3410 abuts one side of the internal flange 3420 of the tubularsleeve 3418, and the internal diameter of the internal flange 3420 ofthe tubular sleeve 3416 is substantially equal to or greater than themaximum internal diameter of the internally threaded connection 3412 ofthe end portion 3416 of the first tubular member 3410. An externallythreaded connection 3428 of an end portion 3430 of a second tubularmember 3432 that includes one or more internal grooves 3434 is thenpositioned within the tubular sleeve 3418 and threadably coupled to theinternally threaded connection 3412 of the end portion 3416 of the firsttubular member 3410. In an exemplary embodiment, the internal flange3420 of the tubular sleeve 3418 mates with and is received within anannular recess 3436 defined in the end portion 3430 of the secondtubular member 3432. Thus, the tubular sleeve 3418 is coupled to andsurrounds the external surfaces of the first and second tubular members,3410 and 3432.

The first and second tubular members, 3410 and 3432, and the tubularsleeve 3418 may be positioned within another structure such as, forexample, a cased or uncased wellbore, and radially expanded andplastically deformed, for example, by displacing and/or rotating aconventional expansion device within and/or through the interiors of thefirst and second tubular members. The tapered portions, 3422 and 3424,of the tubular sleeve 3418 facilitate the insertion and movement of thefirst and second tubular members within and through the structure, andthe movement of the expansion device through the interiors of the firstand second tubular members, 3410 and 3432, may be from top to bottom orfrom bottom to top.

During the radial expansion and plastic deformation of the first andsecond tubular members, 3410 and 3432, the tubular sleeve 3418 is alsoradially expanded and plastically deformed. As a result, the tubularsleeve 3418 may be maintained in circumferential tension and the endportions, 3416 and 3430, of the first and second tubular members, 3410and 3432, may be maintained in circumferential compression.

Sleeve 3416 increases the axial compression loading of the connectionbetween tubular members 3410 and 3432 before and after expansion by theexpansion device. The sleeve 3418 may be secured to tubular members 3410and 3432, for example, by a heat shrink fit.

During the radial expansion and plastic deformation of the first andsecond tubular members, 3410 and 3432, the grooves 3414 and/or 3434and/or the openings 3426 provide stress concentrations that in turnapply added stress forces to the mating threads of the threadedconnections, 3412 and 3428. As a result, during and after the radialexpansion and plastic deformation of the first and second tubularmembers, 3410 and 3432, the mating threads of the threaded connections,3412 and 3428, are maintained in metal to metal contact therebyproviding a fluid and gas tight connection. In an exemplary embodiment,the orientations of the grooves 3414 and/or 3434 and the openings 3426are orthogonal to one another. In an exemplary embodiment, the grooves3414 and/or 3434 are helical grooves.

In several alternative embodiments, the first and second tubularmembers, 3410 and 3432, are radially expanded and plastically deformedusing other conventional methods for radially expanding and plasticallydeforming tubular members such as, for example, internal pressurization,hydroforming, and/or roller expansion devices and/or any one orcombination of the conventional commercially available expansionproducts and services available from Baker Hughes, WeatherfordInternational, and/or Enventure Global Technology L.L.C.

The use of the tubular sleeve 3418 during (a) the coupling of the firsttubular member 3410 to the second tubular member 3432, (b) the placementof the first and second tubular members in the structure, and (c) theradial expansion and plastic deformation of the first and second tubularmembers provides a number of significant benefits. For example, thetubular sleeve 3418 protects the exterior surfaces of the end portions,3416 and 3430, of the first and second tubular members, 3410 and 3432,during handling and insertion of the tubular members within thestructure. In this manner, damage to the exterior surfaces of the endportions, 3416 and 3430, of the first and second tubular members, 3410and 3432, is avoided that could otherwise result in stressconcentrations that could cause a catastrophic failure during subsequentradial expansion operations. Furthermore, the tubular sleeve 3418provides an alignment guide that facilitates the insertion and threadedcoupling of the second tubular member 3432 to the first tubular member3410. In this manner, misalignment that could result in damage to thethreaded connections, 3412 and 3428, of the first and second tubularmembers, 3410 and 3432, may be avoided. In addition, during the relativerotation of the second tubular member with respect to the first tubularmember, required during the threaded coupling of the first and secondtubular members, the tubular sleeve 3416 provides an indication of towhat degree the first and second tubular members are threadably coupled.For example, if the tubular sleeve 3418 can be easily rotated, thatwould indicate that the first and second tubular members, 3410 and 3432,are not fully threadably coupled and in intimate contact with theinternal flange 3420 of the tubular sleeve. Furthermore, the tubularsleeve 3418 may prevent crack propagation during the radial expansionand plastic deformation of the first and second tubular members, 3410and 3432. In this manner, failure modes such as, for example,longitudinal cracks in the end portions, 3416 and 3430, of the first andsecond tubular members may be limited in severity or eliminated alltogether. In addition, after completing the radial expansion and plasticdeformation of the first and second tubular members, 3410 and 3432, thetubular sleeve 3418 may provide a fluid and gas tight metal-to-metalseal between interior surface of the tubular sleeve 3418 and theexterior surfaces of the end portions, 3416 and 3430, of the first andsecond tubular members. In this manner, fluidic materials are preventedfrom passing through the threaded connections, 3412 and 3430, of thefirst and second tubular members, 3410 and 3432, into the annulusbetween the first and second tubular members and the structure.Furthermore, because, following the radial expansion and plasticdeformation of the first and second tubular members, 3410 and 3432, thetubular sleeve 3418 may be maintained in circumferential tension and theend portions, 3416 and 3430, of the first and second tubular members,3410 and 3432, may be maintained in circumferential compression, axialloads and/or torque loads may be transmitted through the tubular sleeve.

In several exemplary embodiments, the first and second tubular membersdescribed above with reference to FIGS. 1 to 34 c are radially expandedand plastically deformed using the expansion device in a conventionalmanner and/or using one or more of the methods and apparatus disclosedin one or more of the following: The present application is related tothe following: (1) U.S. Pat. No. 6,497,289, which was filed as U.S.patent application Ser. No. 09/454,139, attorney docket no. 25791.03.02,filed on Dec. 3, 1999, which claims priority from provisionalapplication 60/111,293, filed on Dec. 7, 1998, (2) U.S. patentapplication Ser. No. 09/510,913, attorney docket no. 25791.7.02, filedon Feb. 23, 2000, which claims priority from provisional application60/121,702, filed on Feb. 25, 1999, (3) U.S. patent application Ser. No.09/502,350, attorney docket no. 25791.8.02, filed on Feb. 10, 2000,which claims priority from provisional application 60/119,611, filed onFeb. 11, 1999, (4) U.S. Pat. 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No. ______,attorney docket no. 25791.307.04, filed on _; and (182) U.S. NationalState patent application Ser. No. ______, attorney docket no.25791.308.07, filed on _, the disclosures of which are incorporatedherein by reference.

Referring to FIG. 35 a an exemplary embodiment of an expandable tubularmember 3500 includes a first tubular region 3502 and a second tubularportion 3504. In an exemplary embodiment, the material properties of thefirst and second tubular regions, 3502 and 3504, are different. In anexemplary embodiment, the yield points of the first and second tubularregions, 3502 and 3504, are different. In an exemplary embodiment, theyield point of the first tubular region 3502 is less than the yieldpoint of the second tubular region 3504. In several exemplaryembodiments, one or more of the expandable tubular members, 12, 14, 24,26, 102, 104, 106, 108, 202 and/or 204 incorporate the tubular member3500.

Referring to FIG. 35 b, in an exemplary embodiment, the yield pointwithin the first and second tubular regions, 3502 a and 3502 b, of theexpandable tubular member 3502 vary as a function of the radial positionwithin the expandable tubular member. In an exemplary embodiment, theyield point increases as a function of the radial position within theexpandable tubular member 3502. In an exemplary embodiment, therelationship between the yield point and the radial position within theexpandable tubular member 3502 is a linear relationship. In an exemplaryembodiment, the relationship between the yield point and the radialposition within the expandable tubular member 3502 is a non-linearrelationship. In an exemplary embodiment, the yield point increases atdifferent rates within the first and second tubular regions, 3502 a and3502 b, as a function of the radial position within the expandabletubular member 3502. In an exemplary embodiment, the functionalrelationship, and value, of the yield points within the first and secondtubular regions, 3502 a and 3502 b, of the expandable tubular member3502 are modified by the radial expansion and plastic deformation of theexpandable tubular member.

In several exemplary embodiments, one or more of the expandable tubularmembers, 12, 14, 24, 26, 102, 104, 106, 108, 202, 204 and/or 3502, priorto a radial expansion and plastic deformation, include a microstructurethat is a combination of a hard phase, such as martensite, a soft phase,such as ferrite, and a transitionary phase, such as retained austentite.In this manner, the hard phase provides high strength, the soft phaseprovides ductility, and the transitionary phase transitions to a hardphase, such as martensite, during a radial expansion and plasticdeformation. Furthermore, in this manner, the yield point of the tubularmember increases as a result of the radial expansion and plasticdeformation. Further, in this manner, the tubular member is ductile,prior to the radial expansion and plastic deformation, therebyfacilitating the radial expansion and plastic deformation. In anexemplary embodiment, the composition of a dual-phase expandable tubularmember includes (weight percentages): about 0.1% C, 1.2% Mn, and 0.3%Si.

In an exemplary experimental embodiment, as illustrated in FIGS. 36 a-36c, one or more of the expandable tubular members, 12, 14, 24, 26, 102,104, 106, 108, 202, 204 and/or 3502 are processed in accordance with amethod 3600, in which, in step 3602, an expandable tubular member 3602 ais provided that is a steel alloy having following material composition(by weight percentage): 0.065% C, 1.44% Mn, 0.01% P, 0.002% S, 0.24% Si,0.01% Cu, 0.01% Ni, 0.02% Cr, 0.05% V, 0.01% Mo, 0.01% Nb, and 0.01% Ti.In an exemplary experimental embodiment, the expandable tubular member3602 a provided in step 3602 has a yield strength of 45 ksi, and atensile strength of 69 ksi.

In an exemplary experimental embodiment, as illustrated in FIG. 36 b, instep 3602, the expandable tubular member 3602 a includes amicrostructure that includes martensite, pearlite, and V, Ni, and/or Ticarbides.

In an exemplary embodiment, the expandable tubular member 3602 a is thenheated at a temperature of 790° C. for about 10 minutes in step 3604.

In an exemplary embodiment, the expandable tubular member 3602 a is thenquenched in water in step 3606.

In an exemplary experimental embodiment, as illustrated in FIG. 36 c,following the completion of step 3606, the expandable tubular member3602 a includes a microstructure that includes new ferrite, grainpearlite, martensite, and ferrite. In an exemplary experimentalembodiment, following the completion of step 3606, the expandabletubular member 3602 a has a yield strength of 67 ksi, and a tensilestrength of 95 ksi.

In an exemplary embodiment, the expandable tubular member 3602 a is thenradially expanded and plastically deformed using one or more of themethods and apparatus described above. In an exemplary embodiment,following the radial expansion and plastic deformation of the expandabletubular member 3602 a, the yield strength of the expandable tubularmember is about 95 ksi.

In an exemplary experimental embodiment, as illustrated in FIGS. 37 a-37c, one or more of the expandable tubular members, 12, 14, 24, 26, 102,104, 106, 108, 202, 204 and/or 3502 are processed in accordance with amethod 3700, in which, in step 3702, an expandable tubular member 3702 ais provided that is a steel alloy having following material composition(by weight percentage): 0.18% C, 1.28% Mn, 0.017% P, 0.004% S, 0.29% Si,0.01% Cu, 0.01% Ni, 0.03% Cr, 0.04% V, 0.01% Mo, 0.03% Nb, and 0.01% Ti.In an exemplary experimental embodiment, the expandable tubular member3702 a provided in step 3702 has a yield strength of 60 ksi, and atensile strength of 80 ksi.

In an exemplary experimental embodiment, as illustrated in FIG. 37 b, instep 3702, the expandable tubular member 3702 a includes amicrostructure that includes pearlite and pearlite striation.

In an exemplary embodiment, the expandable tubular member 3702 a is thenheated at a temperature of 790° C. for about 10 minutes in step 3704.

In an exemplary embodiment, the expandable tubular member 3702 a is thenquenched in water in step 3706.

In an exemplary experimental embodiment, as illustrated in FIG. 37 c,following the completion of step 3706, the expandable tubular member3702 a includes a microstructure that includes ferrite, martensite, andbainite. In an exemplary experimental embodiment, following thecompletion of step 3706, the expandable tubular member 3702 a has ayield strength of 82 ksi, and a tensile strength of 130 ksi.

In an exemplary embodiment, the expandable tubular member 3702 a is thenradially expanded and plastically deformed using one or more of themethods and apparatus described above. In an exemplary embodiment,following the radial expansion and plastic deformation of the expandabletubular member 3702 a, the yield strength of the expandable tubularmember is about 130 ksi.

In an exemplary experimental embodiment, as illustrated in FIGS. 38 a-38c, one or more of the expandable tubular members, 12, 14, 24, 26, 102,104, 106, 108, 202, 204 and/or 3502 are processed in accordance with amethod 3800, in which, in step 3802, an expandable tubular member 3802 ais provided that is a steel alloy having following material composition(by weight percentage): 0.08% C, 0.82% Mn, 0.006% P, 0.003% S, 0.30% Si,0.06% Cu, 0.05% Ni, 0.05% Cr, 0.03% V, 0.03% Mo, 0.01% Nb, and 0.01% Ti.In an exemplary experimental embodiment, the expandable tubular member3802 a provided in step 3802 has a yield strength of 56 ksi, and atensile strength of 75 ksi.

In an exemplary experimental embodiment, as illustrated in FIG. 38 b, instep 3802, the expandable tubular member 3802 a includes amicrostructure that includes grain pearlite, widmanstatten martensiteand carbides of V, Ni, and/or Ti.

In an exemplary embodiment, the expandable tubular member 3802 a is thenheated at a temperature of 790° C. for about 10 minutes in step 3804.

In an exemplary embodiment, the expandable tubular member 3802 a is thenquenched in water in step 3806.

In an exemplary experimental embodiment, as illustrated in FIG. 38 c,following the completion of step 3806, the expandable tubular member3802 a includes a microstructure that includes bainite, pearlite, andnew ferrite. In an exemplary experimental embodiment, following thecompletion of step 3806, the expandable tubular member 3802 a has ayield strength of 60 ksi, and a tensile strength of 97 ksi.

In an exemplary embodiment, the expandable tubular member 3802 a is thenradially expanded and plastically deformed using one or more of themethods and apparatus described above. In an exemplary embodiment,following the radial expansion and plastic deformation of the expandabletubular member 3802 a, the yield strength of the expandable tubularmember is about 97 ksi.

Referring to FIG. 39 a, an example tribological elements in a system4000 for reducing the friction between an expansion cone and a tubularmember during the expansion process, will now be described. In a systemfor reducing the friction between an expansion cone and a tubular memberduring the expansion process, there may be at least three elementscontributing to friction; an expansion device 4002, a lubricant 4004,and a tubular member 4006. Elements in the expansion device 4002 thatmay contribute to friction comprise the following: composition 4008;geometry 4010; surface roughness 4012; texture; 4014 and coating 4016.Elements in the lubricant 4004 that may contribute to friction comprisethe following: composition 4018; environmental issues 4020; and frictionmodifiers. Element in the tubular member 4006 that may contribute tofriction comprise the following: inside diameter roughness 4022; andcoating 4024. Each element may be adjusted in the manner described belowto reduce the friction between an expansion cone and a tubular memberduring the expansion process.

Referring to FIG. 39 b, in an exemplary embodiment, during the radialexpansion process, an expansion cone 5000 radially expands a tubularmember 5005 by moving in an axial direction 5010 relative to the tubularmember 5005. The interface between the outer surface 5010 of the taperedportion 5015 of the expansion cone 5000 and the inner surface 5020 ofthe tubular member 5005 includes a leading edge portion 5025 and atrailing edge portion 5030.

During the radial expansion process, the leading edge portion 5025 maybe lubricated by the presence of lubricating fluids provided ahead ofthe expansion cone 5000. However, because the radial clearance betweenthe expansion cone 5000 and the tubular member 5005 in the trailing edgeportion 5030 during the radial expansion process is typically extremelysmall, and the operating contact pressures between the tubular member5005 and the expansion cone 5000 are extremely high, the quantity oflubricating fluid provided to the trailing edge portion 5030 istypically greatly reduced. In typical radial expansion operations, thisreduction in lubrication in the trailing edge portion 5030 increases theforces required to radially expand the tubular member 5005.

Surface Structure of the Expansion Cone

Referring to FIG. 40, an embodiment of a system for lubricating theinterface between an expansion cone and a tubular member during theexpansion process will now be described. As illustrated in FIG. 40, anexpansion cone 5100, having a front end 5100 a and a rear end 5100 b,includes a tapered portion 5105 having an outer surface 3110, one ormore circumferential grooves 5115 a and 5115 b, and one more internalflow passages 5120 a and 5120 b.

In an exemplary embodiment, the circumferential grooves 5115 arefluidicly coupled to the internal flow passages 5120. In this manner,during the radial expansion process, lubricating fluids are transmittedfrom the area ahead of the front 5100 a of the expansion cone 5100 intothe circumferential grooves 5115 from a lubricant source, such as, forexample, from reservoir 5122 utilizing pump 5124. Thus, the trailingedge portion of the interface between the expansion cone 5100 and atubular member is provided with an increased supply of lubricant,thereby reducing the amount of force required to radially expand thetubular member.

In an exemplary embodiment, the expansion cone 5100 includes a pluralityof circumferential grooves 5115. In an exemplary embodiment, theexpansion cone 5100 includes circumferential grooves 5115 concentratedabout the axial midpoint of the tapered portion 5105 in order to providelubrication to the trailing edge portion of the interface between theexpansion cone 5100 and a tubular member during the radial expansionprocess. In an exemplary embodiment, the circumferential grooves 5115are equally spaced along the trailing edge portion of the expansion cone5100 in order to provide lubrication to the trailing edge portion of theinterface between the expansion cone 5100 and a tubular member duringthe radial expansion process.

In an exemplary embodiment, the expansion cone 5100 includes a pluralityof flow passages 5120 coupled to each of the circumferential grooves5115. In an exemplary embodiment, the cross sectional area of thecircumferential grooves 5115 is greater than the cross sectional area ofthe flow passage 5120 in order to minimize resistance to fluid flow.

Referring to FIG. 41, another exemplary embodiment of a system forlubricating the interface between an expansion cone and a tubular memberduring the expansion process will now be described. As illustrated inFIG. 41, an expansion cone 5200, having a front end 5200 a and a rearend 5200 b, includes a tapered portion 5205 having an outer surface5210, one or more circumferential grooves 5215 a and 5215 b, and one ormore axial grooves 5220 a and 5220 b.

In an exemplary embodiment, the circumferential grooves 5215 arefluidicly coupled to the axial groves 5220. In this manner, during theradial expansion process, lubricating fluids are transmitted from thearea ahead of the front 5200 a of the expansion cone 5200 into thecircumferential grooves 5215. Thus, the trailing edge portion of theinterface between the expansion cone 5200 and a tubular member isprovided with an increased supply of lubricant, thereby reducing theamount of force required to radially expand the tubular member. In anexemplary embodiment, the axial grooves 5220 are provided withlubricating fluid using a supply of lubricating fluid positionedproximate the front end 5200 a of the expansion cone 5200. In anexemplary embodiment, the circumferential grooves 3215 are concentratedabout the axial midpoint of the tapered portion 5205 of the expansioncone 5200 in order to provide lubrication to the trailing edge portionof the interface between the expansion cone 5200 and a tubular memberduring the radial expansion process. In an exemplary embodiment, thecircumferential grooves 5215 are equally spaced along the trailing edgeportion of the expansion cone 5200 in order to provide lubrication tothe trailing edge portion of the interface between the expansion cone5200 and a tubular member during the radial expansion process.

In an exemplary embodiment, the expansion cone 5200 includes a pluralityof circumferential grooves 5215. In an exemplary embodiment, theexpansion cone 5200 includes a plurality of axial grooves 5220 coupledto each of the circumferential grooves 5215. In an exemplary embodiment,the cross sectional area of the circumferential grooves 5215 is greaterthan the cross sectional area of the axial grooves 5220 in order tominimize resistance to fluid flow. In an exemplary embodiment, the axialgroves 5220 are spaced apart in the circumferential direction by atleast about 3 inches in order to provide lubrication during the radialexpansion process.

Referring to FIG. 42, another exemplary embodiment of a system forlubricating the interface between an expansion cone and a tubular memberduring the expansion process will now be described. As illustrated inFIG. 42, an expansion cone 5300, having a front end 5300 a and a rearend 5300 b, includes a tapered portion 5305 having an outer surface5310, one or more circumferential grooves 5315 a and 5315 b, and one ormore internal flow passages 5320 a and 5320 b.

In an exemplary embodiment, the circumferential grooves 5315 arefluidicly coupled to the internal flow passages 5320. In this manner,during the radial expansion process, lubricating fluids are transmittedfrom the areas in front of the front 5300 a and/or behind the rear 5300b of the expansion cone 5300 into the circumferential grooves 5315.Thus, the trailing edge portion of the interface between the expansioncone 5300 and a tubular member is provided with an increased supply oflubricant, thereby reducing the amount of force required to radiallyexpand the tubular member. Furthermore, the lubricating fluids also passto the area in front of the expansion cone. In this manner, the areaadjacent to the front 5300 a of the expansion cone 5300 is cleaned offoreign materials. In an exemplary embodiment, the lubricating fluidsare injected into the internal flow passages 5320 by pressurizing thearea behind the rear 5300 b of the expansion cone 5300 during the radialexpansion process.

In an exemplary embodiment, the expansion cone 5300 includes a pluralityof circumferential grooves 5315. In an exemplary embodiment, theexpansion cone 5300 includes circumferential grooves 5315 that areconcentrated about the axial midpoint of the tapered portion 5305 inorder to provide lubrication to the trailing edge portion of theinterface between the expansion cone 5300 and a tubular member duringthe radial expansion process. In an exemplary embodiment, thecircumferential grooves 5315 are equally spaced along the trailing edgeportion of the expansion cone 5300 in order to provide lubrication tothe trailing edge portion of the interface between the expansion cone5300 and a tubular member during the radial expansion process.

In an exemplary embodiment, the expansion cone 5300 includes a pluralityof flow passages 5320 coupled to each of the circumferential grooves5315. In an exemplary embodiment, the flow passages 5320 fluidiclycoupled the front end 5300 a and the rear end 5300 b of the expansioncone 5300. In an exemplary embodiment, the cross sectional area of thecircumferential grooves 5315 is greater than the cross-sectional area ofthe flow passages 5320 in order to minimize resistance to fluid flow.

Referring to FIG. 43, an embodiment of a system for lubricating theinterface between an expansion cone and a tubular member during theexpansion process will now be described. As illustrated in FIG. 43, anexpansion cone 5400, having a front end 5400 a and a rear end 5400 b,includes a tapered portion 5405 having an outer surface 5410, one ormore circumferential grooves 5415 a and 5415 b, and one or more axialgrooves 5420 a and 5420 b.

In an exemplary embodiment, the circumferential grooves 5415 arefluidicly coupled to the axial grooves 5420. In this manner, during theradial expansion process, lubricating fluids are transmitted from theareas in front of the front 5400 a and/or behind the rear 5400 b of theexpansion cone 5400 into the circumferential grooves 5415. Thus, thetrailing edge portion of the interface between the expansion cone 5400and a tubular member is provided with an increased supply of lubricant,thereby reducing the amount of force required to radially expand thetubular member. Furthermore, In an exemplary embodiment, pressurizedlubricating fluids pass from the fluid passages 5420 to the area infront of the front 5400 a of the expansion cone 5400. In this manner,the area adjacent to the front 5400 a of the expansion cone 5400 iscleaned of foreign materials. In an exemplary embodiment, thelubricating fluids are injected into the internal flow passages 5420 bypressurizing the area behind the rear 5400 b expansion cone 5400 duringthe radial expansion process.

In an exemplary embodiment, the expansion cone 5400 includes a pluralityof circumferential grooves 5415. In an exemplary embodiment, theexpansion cone 5400 includes circumferential grooves 5415 that areconcentrated about the axial midpoint of the tapered portion 5405 inorder to provide lubrication to the trailing edge portion of theinterface between the expansion cone 5400 and a tubular member duringthe radial expansion process. In an exemplary embodiment, thecircumferential grooves 5415 are equally spaced along the trailing edgeportion of the expansion cone 5400 in order to provide lubrication tothe trailing edge portion of the interface between the expansion cone5400 and a tubular member during the radial expansion process.

In an exemplary embodiment, the expansion cone 5400 includes a pluralityof axial grooves 5420 coupled to each of the circumferential grooves5415. In an exemplary embodiment, the axial grooves 5420 fluidiclycoupled the front end and the rear end of the expansion cone 5400. In anexemplary embodiment, the cross sectional area of the circumferentialgrooves 5415 is greater than the cross sectional area of the axialgrooves 5420 in order to minimize resistance to fluid flow. In anexemplary embodiment, the axial grooves 5420 are spaced apart in thecircumferential direction by at least about 3 inches in order to providelubrication during the radial expansion process.

Referring to FIG. 44, another exemplary embodiment of a system forlubricating the interface between an expansion cone and a tubular memberduring the expansion process will now be described. As illustrated inFIG. 44, an expansion cone 5500, having a front end 5500 a and a rearend 5500 b, includes a tapered portion 5505 having an outer surface5510, one or more circumferential grooves 5515 a and 5515 b, and one ormore axial grooves 5520 a and 5520 b.

In an exemplary embodiment, the circumferential grooves 5515 arefluidicly coupled to the axial grooves 5520. In this manner, during theradial expansion process, lubricating fluids are transmitted from thearea ahead of the front 5500 a of the expansion cone 5500 into thecircumferential grooves 5515. Thus, the trailing edge portion of theinterface between the expansion cone 5500 and a tubular member isprovided with an increased supply of lubricant, thereby reducing theamount of force required to radially expand the tubular member. In anexemplary embodiment, the lubricating fluids are injected into the axialgrooves 5520 using a fluid conduit that is coupled to the tapered end3205 of the expansion cone 3200.

In an exemplary embodiment, the expansion cone 5500 includes a pluralityof circumferential grooves 5515. In an exemplary embodiment, theexpansion cone 5500 includes circumferential grooves 5515 that areconcentrated about the axial midpoint of the tapered portion 5505 inorder to provide lubrication to the trailing edge portion of theinterface between the expansion cone 5500 and a tubular member duringthe radial expansion process. In an exemplary embodiment, thecircumferential grooves 5515 are equally spaced along the trailing edgeportion of the expansion cone 5500 in order to provide lubrication tothe trailing edge portion of the interface between the expansion cone5500 and a tubular member during the radial expansion process.

In an exemplary embodiment, the expansion cone 5500 includes a pluralityof axial grooves 5520 coupled to each of the circumferential grooves5515. In an exemplary embodiment, the axial grooves 5520 intersect eachof the circumferential groves 5515 at an acute angle. In an exemplaryembodiment, the cross sectional area of the circumferential grooves 5515is greater than the cross sectional area of the axial grooves 5520. Inan exemplary embodiment, the axial grooves 5520 are spaced apart in thecircumferential direction by at least about 3 inches in order to providelubrication during the radial expansion process. In an exemplaryembodiment, the axial grooves 5520 intersect the longitudinal axis ofthe expansion cone 5500 at a larger angle than the angle of attack ofthe tapered portion 5505 in order to provide lubrication during theradial expansion process.

Referring to FIG. 45, another exemplary embodiment of a system forlubricating the interface between an expansion cone and a tubular memberduring the expansion process will now be described. As illustrated inFIG. 45, an expansion cone 5600, having a front end 5600 a and a rearend 5600 b, includes a tapered portion 5605 having an outer surface5610, a spiral circumferential groove 5615, and one or more internalflow passages 5620.

In an exemplary embodiment, the circumferential groove 5615 is fluidiclycoupled to the internal flow passage 5620. In this manner, during theradial expansion process, lubricating fluids are transmitted from thearea ahead of the front 5600 a of the expansion cone 5600 into thecircumferential groove 5615, such as, for example, from reservoir 5622utilizing pump 5624. Thus, the trailing edge portion of the interfacebetween the expansion cone 5600 and a tubular member is provided with anincreased supply of lubricant, thereby reducing the amount of forcerequired to radially expand the tubular member. In an exemplaryembodiment, the lubricating fluids are injected into the internal flowpassage 5620 using a fluid conduit that is coupled to the tapered end5605 of the expansion cone 5600.

In an exemplary embodiment, the expansion cone 5600 includes a pluralityof spiral circumferential grooves 5615. In an exemplary embodiment, theexpansion cone 5600 includes circumferential grooves 5615 that areconcentrated about the axial midpoint of the tapered portion 5605 inorder to provide lubrication to the trailing edge portion of theinterface between the expansion cone 5600 and a tubular member duringthe radial expansion process. In an exemplary embodiment, thecircumferential grooves 5615 are equally spaced along the trailing edgeportion of the expansion cone 5600 in order to provide lubrication tothe trailing edge portion of the interface between the expansion cone5600 and a tubular member during the radial expansion process.

In an exemplary embodiment, the expansion cone 5600 includes a pluralityof flow passages 5620 coupled to each of the circumferential grooves5615. In an exemplary embodiment, the cross sectional area of thecircumferential groove 5615 is greater than the cross sectional area ofthe flow passage 5620 in order to minimize resistance to fluid flow.

Referring to FIG. 46, another exemplary embodiment of a system forlubricating the interface between an expansion cone and a tubular memberduring the expansion process will now be described. As illustrated inFIG. 46, an expansion cone 5700, having a front end 5700 a and a rearend 5700 b, includes a tapered portion 5705 having an outer surface5710, a spiral circumferential groove 5715, and one or more axialgrooves 5720 a, 5720 b and 5720 c.

In an exemplary embodiment, the circumferential groove 5715 is fluidiclycoupled to the axial grooves 5720. In this manner, during the radialexpansion process, lubricating fluids are transmitted from the areaahead of the front 5700 a of the expansion cone 5700 into thecircumferential groove 5715. Thus, the trailing edge portion of theinterface between the expansion cone 5700 and a tubular member isprovided with an increased supply of lubricant, thereby reducing theamount of force required to radially expand the tubular member. In anexemplary embodiment, the lubricating fluids are injected into the axialgrooves 5720 using a fluid conduit that is coupled to the tapered end5705 of the expansion cone 5700.

In an exemplary embodiment, the expansion cone 5700 includes a pluralityof spiral circumferential grooves 5715. In an exemplary embodiment, theexpansion cone 5700 includes circumferential grooves 5715 concentratedabout the axial midpoint of the tapered portion 5705 in order to providelubrication to the trailing edge portion of the interface between theexpansion cone 5700 and a tubular member during the radial expansionprocess. In an exemplary embodiment, the circumferential grooves 5715are equally spaced along the trailing edge portion of the expansion cone5700 in order to provide lubrication to the trailing edge portion of theinterface between the expansion cone 5700 and a tubular member duringthe radial expansion process.

In an exemplary embodiment, the expansion cone 5700 includes a pluralityof axial grooves 5720 coupled to each of the circumferential grooves5715. In an exemplary embodiment, the axial grooves 5720 intersect thecircumferential grooves 5715 in a perpendicular manner. In an exemplaryembodiment, the cross sectional area of the circumferential groove 5715is greater than the cross sectional area of the axial grooves 5720 inorder to minimize resistance to fluid flow. In an exemplary embodiment,the circumferential spacing of the axial grooves is greater than about 3inches in order to provide lubrication during the radial expansionprocess. In an exemplary embodiment, the axial grooves 5720 intersectthe longitudinal axis of the expansion cone at an angle greater than theangle of attack of the tapered portion 5705 in order to providelubrication during the radial expansion process.

Referring to FIG. 47, an embodiment of a system for lubricating theinterface between an expansion cone and a tubular member during theexpansion process will now be described. As illustrated in FIG. 47, anexpansion cone 5800, having a front end 5800 a and a rear end 5800 b,includes a tapered portion 5805 having an outer surface 5810, acircumferential groove 5815, a first axial groove 5820, and one or moresecond axial grooves 5825 a, 5825 b, 5825 c and 5825 d.

In an exemplary embodiment, the circumferential groove 5815 is fluidiclycoupled to the axial grooves 5820 and 5825. In this manner, during theradial expansion process, lubricating fluids are transmitted from thearea behind the back 5800 b of the expansion cone 5800 into thecircumferential groove 5815. Thus, the trailing edge portion of theinterface between the expansion cone 5800 and a tubular member isprovided with an increased supply of lubricant, thereby reducing theamount of force required to radially expand the tubular member. In anexemplary embodiment, the lubricating fluids are injected into the firstaxial groove 5820 by pressurizing the region behind the back 5800 b ofthe expansion cone 5800. In an exemplary embodiment, the lubricant isfurther transmitted into the second axial grooves 5825 where thelubricant preferably cleans foreign materials from the tapered portion5805 of the expansion cone 5800.

In an exemplary embodiment, the expansion cone 5800 includes a pluralityof circumferential grooves 5815. In an exemplary embodiment, theexpansion cone 5800 includes circumferential grooves 5815 concentratedabout the axial midpoint of the tapered portion 5805 in order to providelubrication to the trailing edge portion of the interface between theexpansion cone 5800 and a tubular member during the radial expansionprocess. In an exemplary embodiment, the circumferential grooves 5815are equally spaced along the trailing edge portion of the expansion cone5800 in order to provide lubrication to the trailing edge portion of theinterface between the expansion cone 5800 and a tubular member duringthe radial expansion process.

In an exemplary embodiment, the expansion cone 5800 includes a pluralityof first axial grooves 5820 coupled to each of the circumferentialgrooves 5815. In an exemplary embodiment, the first axial grooves 5820extend from the back 5800 b of the expansion cone 5800 and intersect thecircumferential groove 5815. In an exemplary embodiment, the first axialgroove 5820 intersects the circumferential groove 5815 in aperpendicular manner. In an exemplary embodiment, the cross sectionalarea of the circumferential groove 5815 is greater than the crosssectional area of the first axial groove 5820 in order to minimizeresistance to fluid flow. In an exemplary embodiment, thecircumferential spacing of the first axial grooves 5820 is greater thanabout 3 inches in order to provide lubrication during the radialexpansion process.

In an exemplary embodiment, the expansion cone 5800 includes a pluralityof second axial grooves 5825 coupled to each of the circumferentialgrooves 5815. In an exemplary embodiment, the second axial grooves 5825extend from the front 5800 a of the expansion cone 5800 and intersectthe circumferential groove 5815. In an exemplary embodiment, the secondaxial grooves 5825 intersect the circumferential groove 5815 in aperpendicular manner. In an exemplary embodiment, the cross sectionalarea of the circumferential groove 5815 is greater than the crosssectional area of the second axial grooves 5825 in order to minimizeresistance to fluid flow. In an exemplary embodiment, thecircumferential spacing of the second axial grooves 5825 is greater thanabout 3 inches in order to provide lubrication during the radialexpansion process. In an exemplary embodiment, the second axial grooves5825 intersect the longitudinal axis of the expansion cone 5800 at anangle greater than the angle of attack of the tapered portion 5805 inorder to provide lubrication during the radial expansion process.

Referring to FIG. 48, an embodiment of a system for lubricating theinterface between an expansion cone and a tubular member during theexpansion process will now be described. As illustrated in FIG. 48, anexpansion cone 5900, having a front end 5900 a and a rear end 5900 b,includes a tapered portion 5905 having an outer surface 5910, one ormore circumferential grooves 5915 a and 5915 b, one or more radialpassageways 5916 and one more internal flow passages 5920.

In an exemplary embodiment, the circumferential groove 5915 a isfluidicly coupled to the internal flow passages 5920. In this manner,during the radial expansion process, lubricating fluids are transmittedfrom the area ahead of the front 5900 a of the expansion cone 5900 intothe circumferential grooves 5915, such as, for example, from reservoir5922 utilizing pump 5924. Thus, the trailing edge portion of theinterface between the expansion cone 5900 and a tubular member isprovided with an increased supply of lubricant, thereby reducing theamount of force required to radially expand the tubular member.

In an exemplary embodiment, the expansion cone 5900 includes a pluralityof circumferential grooves 5915 a. In an exemplary embodiment, theexpansion cone 5900 includes circumferential grooves 5915 a concentratedabout the axial midpoint of the tapered portion 5905 in order to providelubrication to the trailing edge portion of the interface between theexpansion cone 5900 and a tubular member during the radial expansionprocess. In an exemplary embodiment, the circumferential grooves 5915are equally spaced along the trailing edge portion of the expansion cone5900 in order to provide lubrication to the trailing edge portion of theinterface between the expansion cone 5900 and a tubular member duringthe radial expansion process.

In an exemplary embodiment, the expansion cone 5900 includes a pluralityof flow passages coupled to each of the circumferential grooves 5915 a.In another embodiment, circumferential groove 5915 b, which is notfluidicly coupled to the internal flow passages, may also be included.

Referring to FIG. 49, an embodiment of a system for lubricating theinterface between an expansion cone and a tubular member during theexpansion process will now be described. As illustrated in FIG. 49, anexpansion cone 6000, having a front end 6000 a and a rear end 6000 b,includes a tapered portion 6005 having an outer surface 6010, one ormore circumferential grooves 6015, one or more radial passageways 6016and one or more internal flow passages 6020.

In an exemplary embodiment, the circumferential grooves 6015 arefluidicly coupled to the internal flow passages 6020. In this manner,during the radial expansion process, lubricating fluids are transmittedfrom the area ahead of the front 6000 a of the expansion cone 6000 intothe circumferential grooves 6015, such as, for example, from reservoir6022 utilizing pump 6024. Thus, the trailing edge portion of theinterface between the expansion cone 6000 and a tubular member isprovided with an increased supply of lubricant, thereby reducing theamount of force required to radially expand the tubular member.

In an exemplary embodiment, the expansion cone 6000 includes a pluralityof circumferential grooves 6015. In an exemplary embodiment, theexpansion cone 6000 includes circumferential grooves 6015 concentratedabout the axial midpoint of the tapered portion 6005 in order to providelubrication to the trailing edge portion of the interface between theexpansion cone 6000 and a tubular member during the radial expansionprocess. In an exemplary embodiment, the circumferential grooves 6015are equally spaced along the trailing edge portion of the expansion cone6000 in order to provide lubrication to the trailing edge portion of theinterface between the expansion cone 6000 and a tubular member duringthe radial expansion process.

In an exemplary embodiment, the expansion cone 6000 includes a pluralityof flow passages coupled to each of the circumferential grooves 6015.

Referring to FIG. 50, an embodiment of a system for lubricating theinterface between an expansion cone and a tubular member during theexpansion process will now be described. As illustrated in FIG. 50, anexpansion cone 6100, having a front end 6100 a and a rear end 6100 b,includes a tapered portion 6105 having an outer surface 6110, one ormore circumferential grooves 6115 a and 6115 b, one or more radialpassageways 6116 and one more internal flow passages 6120.

In an exemplary embodiment, the circumferential groove 6115 a isfluidicly coupled to the internal flow passages 6120. In this manner,during the radial expansion process, lubricating fluids are transmittedfrom the area ahead of the front 6100 a of the expansion cone 6100 intothe circumferential grooves 6115, such as, for example, from reservoir6122 utilizing pump 6124. Thus, the trailing edge portion of theinterface between the expansion cone 6100 and a tubular member isprovided with an increased supply of lubricant, thereby reducing theamount of force required to radially expand the tubular member.

In an exemplary embodiment, the expansion cone 6100 includes a pluralityof circumferential grooves 6115 a. In an exemplary embodiment, theexpansion cone 6100 includes circumferential grooves 6115 a concentratedabout the axial midpoint of the tapered portion 6105 in order to providelubrication to the trailing edge portion of the interface between theexpansion cone 6100 and a tubular member during the radial expansionprocess. In an exemplary embodiment, the circumferential grooves 6115 aare equally spaced along the trailing edge portion of the expansion cone6100 in order to provide lubrication to the trailing edge portion of theinterface between the expansion cone 6100 and a tubular member duringthe radial expansion process.

In an exemplary embodiment, the expansion cone 6100 includes a pluralityof flow passages coupled to each of the circumferential grooves 6115 a.Alternatively, circumferential groove 6115 b, which is not fluidiclycoupled to the internal flow passages, may also be included.

Referring to FIG. 51, another exemplary embodiment of a system forlubricating the interface between an expansion cone and a tubular memberduring the expansion process will now be described. As illustrated inFIG. 51, an expansion cone 6200, having a front end 6200 a and a rearend 6200 b, includes a tapered portion 6205 having an outer surface6210, circumferential grooves 6215 arranged in a helical crisscrossingpattern, one or more radial passageways 6216 and one or more internalflow passages 6220.

In an exemplary embodiment, the circumferential grooves 6215 arefluidicly coupled to each other and to the internal flow passages 6220.In this manner, during the radial expansion process, lubricating fluidsare transmitted from the area ahead of the front 6200 a of the expansioncone 6200 into the circumferential grooves 6215, such as, for example,from reservoir 6222 utilizing pump 6224. Thus, the trailing edge portionof the interface between the expansion cone 6200 and a tubular member isprovided with an increased supply of lubricant, thereby reducing theamount of force required to radially expand the tubular member.

In an exemplary embodiment, the expansion cone 6200 includes a pluralityof circumferential grooves 6215 arranged in a pinecone design. In anexemplary embodiment, the expansion cone 6200 includes circumferentialgrooves 6215 concentrated about the axial midpoint of the taperedportion 6205 in order to provide lubrication to the trailing edgeportion of the interface between the expansion cone 6200 and a tubularmember during the radial expansion process. In an exemplary embodiment,the circumferential grooves 6215 are equally spaced along the trailingedge portion of the expansion cone 6200 in order to provide lubricationto the trailing edge portion of the interface between the expansion cone6200 and a tubular member during the radial expansion process.

Referring to FIG. 52, an alternate exemplary embodiment of the systemfor lubricating the interface between an expansion cone and a tubularmember during the expansion process shown in FIG. 51 will now bedescribed. As illustrated in FIG. 52, an expansion cone 6200, having afront end 6200 a and a rear end 6200 b, includes a tapered portion 6205having an outer surface 6210, circumferential grooves 6215 arranged in ahelical crisscrossing pattern over the entire outer surface 6210, one ormore radial passageways 6216 and one or more internal flow passages6220.

In an exemplary embodiment, the circumferential grooves 6218 arefluidicly coupled to each other and to the internal flow passages 6220.In this manner, during the radial expansion process, lubricating fluidsare transmitted from the area ahead of the front 6200 a of the expansioncone 6200 into the circumferential grooves 6218, such as, for example,from reservoir 6222 utilizing pump 6224. Thus, the trailing edge portionof the interface between the expansion cone 6200 and a tubular member isprovided with an increased supply of lubricant, thereby reducing theamount of force required to radially expand the tubular member.

In an exemplary embodiment, a second circumferential groove 6226 isfluidicly coupled to the circumferential grooves 6218.

Referring to FIG. 53, another exemplary embodiment of a system forlubricating the interface between an expansion cone and a tubular memberduring the expansion process will now be described. As illustrated inFIG. 53, an expansion cone 6300, having a front end 6300 a and a rearend 6300 b, includes a tapered portion 6305 having an outer surface6310, circumferential grooves 6315 arranged in a helical crisscrossingpattern, one or more radial passageways 6316 and one or more internalflow passages 6320.

In an exemplary embodiment, the circumferential grooves 6315 arefluidicly coupled to each other and one more internal flow passages6320. In this manner, during the radial expansion process, lubricatingfluids are transmitted from the area ahead of the front 6300 a of theexpansion cone 6300 into the circumferential grooves 6315, such as, forexample, from reservoir 6322 utilizing pump 6324. Thus, the trailingedge portion of the interface between the expansion cone 6300 and atubular member is provided with an increased supply of lubricant,thereby reducing the amount of force required to radially expand thetubular member. In an exemplary embodiment, the lubricating fluids areinjected into the axial grooves 6320 using a fluid conduit that iscoupled to the tapered end 6305 of the expansion cone 6300.

In an exemplary embodiment, the expansion cone 6300 includes a pluralityof spiral circumferential grooves 6315. In an exemplary embodiment, theexpansion cone 6300 includes circumferential grooves 6315 concentratedabout the axial midpoint of the tapered portion 6305 in order to providelubrication to the trailing edge portion of the interface between theexpansion cone 6300 and a tubular member during the radial expansionprocess. In an exemplary embodiment, the circumferential grooves 6315are equally spaced along the trailing edge portion of the expansion cone6300 in order to provide lubrication to the trailing edge portion of theinterface between the expansion cone 6300 and a tubular member duringthe radial expansion process. In an exemplary embodiment, the axialgrooves 6320 intersect each other in a perpendicular manner.

Referring to FIG. 54, an alternate exemplary embodiment of the a systemfor lubricating the interface between an expansion cone and a tubularmember during the expansion process shown in FIG. 53 will now bedescribed. As illustrated in FIG. 54, an expansion cone 6300, having afront end 6300 a and a rear end 6300 b, includes a tapered portion 6305having an outer surface 6310, circumferential grooves 6315 arranged in ahelical crisscrossing pattern over the substantially all of the outersurface 6310, one or more radial passageways 6316 and one more internalflow passages 6320.

In an exemplary embodiment, the circumferential grooves 6318 arefluidicly coupled to each other and to the internal flow passages 6320.In this manner, during the radial expansion process, lubricating fluidsare transmitted from the area ahead of the front 6300 a of the expansioncone 6300 into the circumferential grooves 6318, such as, for example,from reservoir 6322 utilizing pump 6324. Thus, the trailing edge portionof the interface between the expansion cone 6300 and a tubular member isprovided with an increased supply of lubricant, thereby reducing theamount of force required to radially expand the tubular member.

In an exemplary embodiment, a second circumferential groove 6326 isfluidicly coupled to the circumferential grooves 6318.

Referring to FIG. 55, in an exemplary embodiment, circumferential groove6415 may be utilized on the outer surfaces 5101, 5210, 5310, 5410, 5510,5610, 5710, 5810, 5910, 6010, 6110, 6210, and 6310 in one or more ofexpansion cones 5100, 5200, 5300, 5400, 5500, 5600, 5700, 5800, 5900,6000, 6100, 6200, and 6300. Furthermore, it may be implemented in anyexpansion device including one or more expansion surfaces. In anexemplary embodiment, circumferential groove 6415 is positioned intapered portion 6405 with first edge 6430 on outer surface 6410 a havinga first radius of curvature and second edge 6434 on outer surface 6410 bhaving a second radius of curvature. The radius on the trailing edge6434 may be much larger than the radius on the leading edge 6430 toassist lubricant delivery.

Referring to FIG. 56, in an exemplary embodiment, outer surfaces 6410 aand 6410 b of tapered portion 6405 are tapered at angle β. The anglethat is generated by radius of curvature of second edge 6434 and thetubular member is the sliding angle, which may be important for adequatedelivery of lubricant. If the sliding angle is too large or too small,then the trailing edge may act as a wiper, which may remove lubricantform the working area. The radius of curvature of second edge 6434 andthe sliding angle are at least dependent on the lubricant viscosity,pipe diameter and friction between the expansion cone and the tubularmember. Each cone surface channel design may be empirically design bytesting cones in stages to determine the optimum friction-reducingconfiguration.

In an exemplary embodiment, outer surfaces 6410 a and 6410 b of taperedportion 6405 are tapered at angle β. In an exemplary embodiment, theangle β may range from 8.5 degrees to 12.5 degrees, such as, forexample, 10 degrees. The width 6442 of circumferential groove 6415 maybe as small as possible to maximize the area of outer surfaces 6410 aand 6410 b in contact with the inner surface of the tubular member forradial expansion. In an exemplary embodiment, the radius of curvature6446 of second edge 6434, which may be defined as the perpendicular tothe tangent 6448 at the point where vertical projection line 6450intersects second edge 6434, may be positioned relative to the bottom ofcircumferential groove at angle α, the sliding angle. In an exemplaryembodiment, angle α may be less than or equal to 30 degrees, such as,for example 10 degrees, causing lubricant in the circumferential groove6415 to be drawn efficiently on to the inner surface of the tubularmember during radial expansion.

Referring to FIG. 57, In an exemplary embodiment, circumferential groove6518 may be achieved by indenting a portion of the expansion cone on thetapered portion 6505 a thereby creating a lip 6515 between taperedportion 6505 a and second tapered portion 6505 b. In an exemplaryembodiment, tapered portions, 6505 a and 6505 b, are at the same angleβ. Width y of circumferential groove 6518 from lip 6515 to the locationwhere taper portion 6505 b is at the same angle β tapered portion 6505 amay be wide enough to supply sufficient lubricant to the tubular member,thereby reducing the amount of force required to radially expand thetubular member. Vertical portion 6520 in tapered portion 6505 a havingwidth x exists to reduce the mechanical stress at corner 6552 due tocorner loading. The vertical portion 6520 is not critical to theoperation of the circumferential groove 6518 and hence the width x ofthe vertical portion 6520 is not critical. However, width x of verticalportion 6520 may be small enough to maximize the amount of contactbetween the expansion cone and the tubular member during radialexpansion, yet large enough to reduce the mechanical stress at corner6552. In determining the width x of the vertical portion 6520 and widthy of the circumferential groove 6518 under lip 6515, the followingfactors may be addressed: the size of the expansion cone; the viscosityof the lubricant; and the lubrication injection pressure. Width y of thecircumferential groove 6518 may be as small possible to maximize thearea of outer surfaces, 6510 a and 6510 b, in contact with the surfaceof the tubular member for radial expansion.

Referring to FIGS. 58 a, 58 b and 58 c, an exemplary embodiment of asystem for lubricating the interface between an expansion cone and atubular member during the expansion process shown will now be described.As illustrated in FIGS. 58 a, 58 b and 58 c, expansion cone 6600, havinga front end 6600 a and a rear end 6600 b, includes a tapered portions6605 a and 6605 b and lip 6615.

In an exemplary embodiment, the circumferential groove 6618 under lip6615 is fluidicly coupled to the internal flow passages 6660 throughport 6662. In this manner, during the radial expansion process,lubricating fluids are transmitted from the area ahead of the front end6600 a of the expansion cone 6600 under lip 6615. Thus, the trailingedge portion of the interface between the expansion cone 6600 and atubular member is provided with an increased supply of lubricant,thereby reducing the amount of force required to radially expand thetubular member.

In an exemplary embodiment, exemplary relative dimensions of theelements of FIGS. 58 a, 58 b and 58 c are as follows:

1. taper angle N of tapered portions 6605 a and 6605 b—10 degrees;

2. width x—0.125;

3. radius of curvature of the top edge 6670—0.500;

4. radius of curvature of the first edge 6650—0.02;

5. width of the circumferential groove 6618 under lip 6615—0.020-0.060;

6. height of the cone 6672—1.887;

7. height 6682 of the expansion cone beneath the tapered portion 6605b—0.895;

8. diameter 6678 of the cone at front end 6600 a—1.380.

9. diameter 6676 of the cone at rear end 6600 b—1.656; and

10. depth 6680 of the vertical portion between the top and firstedges—0.015.

Referring to FIGS. 59 a and 59 b, another exemplary embodiment of asystem for lubricating the interface between an expansion cone and atubular member during the expansion process will now be described. Asillustrated in FIGS. 59 a and 59 b, an expansion cone 6700, having afront end 6700 a and a rear end 6700 b, includes a tapered portion 6705having an outer surface 6710, internal flow passage 6730 and one or moreaxial grooves 6720.

In an exemplary embodiment, during the radial expansion process, theaxial grooves 6720 may be fluidicly coupled to the area ahead of thefront end 6700 a of the expansion cone 6700 to receive lubricant. Thus,the trailing edge portion of the interface between the expansion coneand a tubular member is provided with an increased supply of lubricant,thereby reducing the amount of force required to radially expand thetubular member. In an exemplary embodiment, the axial grooves 6720 areprovided with lubricating fluid using a supply of lubricating fluidpositioned proximate the front end 6700 a of the expansion cone 6700.

In an exemplary embodiment, example relative dimensions of the elementsof in FIGS. 59 a and 59 b are as follows:

1. taper angle β of tapered portion 6605—10 degrees;

2. channel 6720 depth—0.020;

3. channel 6720 diameter—0.040;

4. radius of curvature of the bottom of taper portion 6705—0.500;

5. number of axial grooves 6720—8;

6. height of the expansion cone 6700—1.678;

7. height of the expansion cone 6700 beneath the tapered portion6705—0.895;

8. diameter 6778 of the expansion cone 6700 at front end 6600 a—1.380;and

9. diameter 6776 of the expansion cone 6700 at rear end 6600 b—1.656.

Referring to FIGS. 60 a, 60 b and 60 c, another exemplary embodiment ofa system for lubricating the interface between an expansion cone and atubular member during the expansion process will now be described. Asillustrated in FIGS. 60 a, 60 b and 60 c, an expansion cone 6800, havinga front end 6800 a and a rear end 6800 b, includes a tapered portion6805 having an outer surface 6810, which includes a tapered facetedpolygonal outer expansion surface 6802. Tapered faceted polygonal outerexpansion surface 6802 includes circumferential spaced apart contactpoints 6810 that may be in contact with the inside surface of a tubularmember during radial expansion and recesses 6912. When expansion conecircumferential spaced apart contact points 6810 are in contact with atubular member 6820, the recesses 6812 combine with the inside surfaceof the tubular member to form lubricant gaps 6822 between the tubularmember, circumferential spaced apart contact points 6810 and recesses6812. The lubricant gaps may act as a high-pressure lubrication channel.Internal passageway 6804 is fluidicly connected to radial ports 6806,which may supply lubricant to lubricant gaps.

Referring to FIGS. 61 a, 61 b, 61 c, 61 d and 61 e another exemplaryembodiment of a system shown in for lubricating the interface between anexpansion cone having tapered faceted polygonal outer expansion surfaceand a tubular member during the expansion process will now be described.As illustrated in FIGS. 61 a and 61 b, an expansion cone 6900, includescircumferential spaced apart contact points 6910, recesses 6912 aroundthe perimeter of the expansion cone, internal passage 6930 for drillingfluid, internal passages 6914 for lubricating fluids, and radialpassageways 6916.

FIGS. 61 c and 61 d illustrate expansion cone 6900 in contact withtubular member 6920 at circumferential spaced apart contact points 6910around the perimeter of expansion cone 6900. Lubricant gaps 6922 existbetween recesses 6912 and tubular member 6920 and are fluidicly coupledto internal passages 6914 to act as a high-pressure lubrication channelsto increased supply of lubricant, thereby reducing the amount of forcerequired to radially expand tubular member 6920. Lubricant gaps 6922provide additional high-pressure lubrication channels, which may assistin lubricating the tubular member where needed most, at the high loadcontact edge.

Referring to FIG. 61 e, an expansion cone having a tapered facetedpolygonal outer expansion surface with contact points, such as, forexample, circumferential spaced apart contact points 6910 and 6910, maycompensate for non-uniform wall thickness tubular member 6940, byapplying localized higher loads at the polygon contact points. In anexemplary embodiment of expansion cone 6900 having tapered facetedpolygonal outer expansion surface in contact with tubular member 6940having a non-uniform wall thickness is shown. The high loadcircumferential spaced apart contact points may radially expand andplastically deform the thick wall areas T2 as well as the thin wallareas T1, instead of taking the path of least resistance, which mayassist in maintaining a proportional wall thickness during the radialexpansion and plastic deformation process.

The number of circumferential spaced apart contact points, 6810 and6910, having width (W) around the circumference of an expansion cone mayvary for different sizes of expandable tubular members. Several factorsmay be considered when determining the appropriate number contactpoints, 6810 and 6910, such as, for example, the coefficient of frictionbetween the expansion cone and the expandable tubular member, pipequality, and data from lubrication tests. For the ideal tubular memberwith uniform thickness, the number of circumferential spaced apartcontact points may be infinity. Thus, the dimensions of the final designof an expansion cone may ultimately be refined by performing anempirical study.

In an exemplary embodiment, the following equations may be used to makea preliminary calculation of the optimum number of circumferentialspaced apart contact points, 6810 and 6910, on an expansion cone, 6800and 6900, having a tapered faceted polygonal outer expansion surface forexpanding an expandable tubular member having an original insidediameter of 4.77″ to an inside diameter of 5.68″ utilizing an expansioncone, including a lubricant gap depth of 0.06″:R=(D ₁ +D _(exp))/²=(4.77−5.68)/2=0.42;  (5)Sin(α/2)=1−(H/R)=1−(0.06/0.42);  (6)α/2=12.3°;  (7)α=24.6;  (8)N=360°/α=360°/24.6°=15;  (9)where,

D₁=Original tubular member inside diameter;

D_(exp)=Expanded tubular member inside diameter;

H=Gap between gap surface and tubular member inside diameter;

R=Radius of polygon at midpoint of expansion cone;

α=Angle between circumferential spaced apart contact points of polygon;and

N=Number of polygon flat surfaces.

Accordingly, the theoretical number (N) of circumferential spaced apartcontact points, 6810 and 6910, on an expansion cone having a taperedfaceted polygonal outer expansion surface is 15, but the actual numberthat may result from an empirical analysis may depend on tubular memberquality, coefficient of friction, and data from lubrication tests. In anexemplary embodiment, a range for the actual number (N) ofcircumferential spaced apart contact points necessary to expand anexpandable tubular member having an original inside diameter of 4.77″ toan inside diameter of 5.68″ I.D. may range from 12-15.

Referring to FIGS. 62 a, 62 b and 62 c, another exemplary embodiment ofthe system shown in FIGS. 60 a and 60 b for lubricating the interfacebetween an expansion cone having tapered faceted polygonal outerexpansion surface and a tubular member during the expansion process willnow be described. As illustrated in FIG. 62 a, an expansion cone 7000,having a front end 7000 a and a rear end 7000 b, includes a taperedportion 7005, contact surfaces 7010, recesses 7012, internal passage7030 for drilling fluid, internal passages 7014 for lubricating fluids,and radial passageways 7016. The width 7020 of contact surfaces 7010 ofexpansion cone 7000 may be constant for the length of the cone,resulting in trapezoidal shaped lubricant gap 7022 between each contactsurface 7010. The following equations may be used for calculating thewidth (W) 7020 of the contact surface:W=[2R sin(α/2)]/K;  (10)R=(D1+D2)/4;  (11)α=360 degrees/N;  (12)where:

W=Width of contact point;

D1=initial tubular member diameter;

D2=expanded diameter;

N=Number of polygon flat surfaces; and

K=System friction coefficient that must be determined.

In an exemplary embodiment, K is between 3 to 5 for an expandabletubular member having an original inside diameter of 4.77″ and anexpanded inside diameter of 5.68″ may range from 12-15. In an exemplaryembodiment, K is 4.2.

Referring now to FIG. 62 d, 62 e and 62 f another exemplary embodimentof the system shown in FIGS. 60 a, 60 b and 61 for lubricating theinterface between an expansion cone having tapered faceted polygonalouter expansion surface and a tubular member during the expansionprocess will now be described. As illustrated in FIG. 62 b, an expansioncone 7100, having a front end 7100 a and a rear end 7100 b, includes atapered portion 7105, contact surfaces 7110, recesses 7112, internalpassage 7130 for drilling fluid, internal passages 7114 for lubricatingfluids, and radial passageways 7116. The width 7120 of contact surfaces7110 of expansion cone 7100 may vary the length of the cone. In anexemplary embodiment, width 7120 of contact surfaces 7110 may be largerat the front end 7100 a W1 and become smaller toward the rear end 7100 bW2.

In several exemplary embodiments, tapered faceted polygonal outerexpansion surface of an expansion cone may be implemented in anyexpansion cone, including one or more of expansion cones 5100, 5200,5300, 5400, 5500, 5600, 5700, 5800, 5900, 6000, 6100, 6200, 6300 and6600. Furthermore, it may be implemented in any expansion deviceincluding one or more expansion surfaces.

The angle of the tapered portion of each expansion cone, the cone angle,in the system for lubricating the interface between an expansion coneand a tubular member during the expansion process, including the taperedportions in expansion cones 5100, 5200, 5300, 5400, 5500, 5600, 5700,5800, 5900, 6000, 6100, 6200, 6300, 6600, 6700, 6800, 6900, 7000 and7100, may be dependant on the amount of friction between the taperedportion of the expansion cone and the inside diameter of the tubularmember. In an exemplary experimental embodiment, a cone angle of 8.5° to12.5° was shown to be sufficient to expand an expandable tubular memberhaving an original inside diameter of 4.77″ to an inside diameter of5.68″. The optimum cone angle may be determined after testing thelubricant system to determine the exact coefficient of friction. A coneangle greater than 10° may be required to minimize the effect ofthinning the tubular member wall during expansion and may potentiallyreduce failures related to collapsing.

In several exemplary embodiments, one or more of the expansion cones5100, 5200, 5300, 5400, 5500, 5600, 5700, 5800, 5900, 6000, 6100, 6200,6300, 6600, 6700, 6800, 6900, 7000 and 7100 may or may not have internalpassages. In another embodiment, a plurality of inserts having internalflow passages may be provided in the expansion cone internal flowpassages. The internal flow passages of each insert may vary in size. Inthis manner, a expansion cone flow passage may be machined to a standardsize, and the lubricant supply may be varied by using different insertshaving different sized internal flow passages. Each insert may include afilter for filtering particles and other foreign materials from thelubricant that passes into the flow passage. In this manner, the foreignmaterials are prevented from clogging the flow passage and other flowpassages.

Lubricant Delivery System

Regardless of the type of expansion device used in the system forlubricating the interface between an expansion cone and a tubular memberduring the expansion process, including, for example, expansion cones5100, 5200, 5300, 5400, 5500, 5600, 5700, 5800, 5900, 6000, 6100, 6200,6300, 6600, 6700, 6800, 6900, 7000 and 7100, lubricants utilized in thesystems may be provided to the system in various manners. In anexemplary embodiment, lubricating fluids are provided to the internalflow passages or axial groove in expansion cones 5100, 5200, 5300, 5400,5500, 5600, 5700, 5800, 5900, 6000, 6100, 6200, 6300, 6600, 6700, 6800,6900, 7000 and 7100 using a supply of lubricating fluids providedadjacent to the front end 5100 a, 5200 a, 5300 a, 5400 a, 5500 a, 5600a, 5700 a, 5800 a, 5900 a, 6000 a, 6100 a, 6200 a, 6300 a, 6600 a, 6700a, 6800 a, 6900 a, 7000 a and 7100 a, of the expansion cones 5100, 5200,5300, 5400, 5500, 5600, 5700, 5800, 5900, 6000, 6100, 6200, 6300, 6600,6700, 6800, 6900, 7000 and 7100. In another exemplary embodiment,lubricating fluids may provided to the internal flow passages or axialgroove in expansion cones 5100, 5200, 5300, 5400, 5500, 5600, 5700,5800, 5900, 6000, 6100, 6200, 6300, 6600, 6700, 6800, 6900, 7000 and7100 using a supply of lubricating fluids provided adjacent to the rearend 5100 a, 5200 a, 5300 a, 5400 a, 5500 a, 5600 a, 5700 a, 5800 a, 5900a, 6000 a, 6100 a, 6200 a, 6300 a, 6600 a, 6700 a, 6800 a, 6900 a, 7000a and 7100 a, of the expansion cones 5100, 5200, 5300, 5400, 5500, 5600,5700, 5800, 5900, 6000, 6100, 6200, 6300, 6600, 6700, 6800, 6900, 7000and 7100. Alternatively, the lubricating fluids may be injected into anyinternal flow passages in expansion cones 5100, 5200, 5300, 5400, 5500,5600, 5700, 5800, 5900, 6000, 6100, 6200, 6300, 6600, 6700, 6800, 6900,7000 and 7100 using a fluid conduit that is fluidicly coupled to thetapered ends of the expansion cones expansion cones 5100, 5200, 5300,5400, 5500, 5600, 5700, 5800, 5900, 6000, 6100, 6200, 6300, 6600, 6700,6800, 6900, 7000 and 7100.

Referring to FIG. 63, an embodiment of a system 7200 for lubricating theinterface between an expansion cone and a tubular member during theexpansion process will now be described. As illustrated in FIG. 63, anexpansion cone 7202 includes a body 7204 that defines a centrallypositioned longitudinal passage 7206, an internal annular recess 7208,an external annular recess 7210, longitudinal passages, 7212 a and 7212b, fluidicly coupled between the internal and external annular recesses,longitudinal passages, 7214 a and 7214 b, fluidicly coupled to theexternal annular recess, radial passages, 7216 a, 7216 b, and 7216 c,fluidicly coupled to the longitudinal passage 7214 a, and radialpassages, 7218 a, 7218 b, and 7218 c, fluidicly coupled to thelongitudinal passage 7214 b, and includes a front end face 7220, a rearend face 7222, and a tapered external expansion surface 7224 includingspaced apart external grooves, 7224 a, 7224 b, and 7224 c, that arefluidicly coupled to the radial passages, 7214 a, 7216 a, 7214 b, 7216b, 7214 c, and 7216 c, respectively. Spring-biased check valves, 7226 aand 7226 b, are received within, mate with, and are operably coupled to,the longitudinal passages, 7214 a and 7214 b, respectively, forcontrolling the flow of fluidic materials therethrough. A tubular member7228 that defines a longitudinal passage 7228 a and radial passages,7228 b and 7228 c, that are fluidicly coupled to the internal annularrecess 7208 of the expansion cone 7202 is received within, mates with,and is coupled to the centrally positioned longitudinal passage 7206 ofthe expansion cone.

In an exemplary embodiment, during operation of the system 7200, theexpansion cone 7202 is positioned within, and displaced relative to, anexpandable tubular member 7230 thereby radially expanding andplastically deforming the expandable tubular member. In an exemplaryembodiment, the expansion cone 7202 is displaced relative to theexpandable tubular member 7230 by injecting a pressurized fluidicmaterial 7232 into and through the passage 7228 a of the tubular member7228. As a result, the expansion cone 7202 is displaced in a direction7233 relative to the expandable tubular member 7230. In an exemplaryembodiment, the fluidic material 7232 includes one or more lubricantmaterials suitable for lubricating the interface between the expansioncone 7202 and the expandable tubular member 7230 during the radialexpansion process. In particular, in an exemplary embodiment, thefluidic material 7232 is conveyed through the radial passages, 7228 band 7228 c, of the tubular member 7228 into a annular chamber 7234defined between the internal annular recess 7208 of the expansion cone7202 and the tubular member 7228. If the operating pressure of thefluidic material 7232 exceeds a predetermined value, which will vary asa function of the operating characteristics of the check valves, 7226 aand 7226 b, the fluidic material is then conveyed through thelongitudinal passages, 7212 a and 7212 b, into an annular chamber 7236defined between the external annular recess 7210 of the expansion cone7202 and the expandable tubular member 7230. The pressurized fluidicmaterial 7232 is then conveyed into the external grooves, 7224 a, 7224b, and 7224 c, through the longitudinal passages, 7214 a and 7214 b, andthe radial passages, 7216 a, 7216 b, 7216 c, 7218 a, 7218 b, and 7218 c,into the interface between the expansion cone 7202 and the expandabletubular member 7230.

In an exemplary embodiment, the rate of injection of the fluidicmaterial 7232 into the external grooves, 7224 a, 7224 b, and 7224 c,depends on the operating pressure of the fluidic material and theoperating characteristics of the spring-biased check valves, 7226 a and7226 b. In this manner, during the radial expansion process, the fluidicmaterial 7232 may be controllably injected and metered into theinterface between the tapered external expansion surface 7224 of theexpansion cone 7202 and the expandable tubular member 7230 continuouslyduring the radial expansion and plastic deformation of the tubularmember. In an exemplary embodiment, the fluidic material 7232 may beinjected into the external grooves, 7224 a, 7224 b, and 7224 c only whenrequired, or as desired. Thus, the trailing edge portion of theinterface between the tapered external expansion surface 7224 of theexpansion cone 7202 and the expandable tubular member 7230 may beprovided with an increased supply of lubricant, thereby reducing theamount of force required to radially expand and plastically deform theexpandable tubular member.

In an alternate embodiment, the spring-biased check valves, 7226 a and7226 b, may be omitted, and/or used in combination with other types offlow metering devices such as, for example, passive flow controldevices, active flow control devices, fixed orifices, and/or variableorifices.

Referring to FIG. 64, an embodiment of a system 7300 for lubricating theinterface between an expansion cone and a tubular member during theexpansion process will now be described. As illustrated in FIG. 64, anexpansion cone 7302 includes a body 7304 that defines a centrallypositioned longitudinal passage 7306, an internal annular recess 7308,longitudinal passages, 7314 a and 7314 b, fluidicly coupled to theinternal annular recess 7308, radial passages, 7316 a, 7316 b, and 7316c, fluidicly coupled to the longitudinal passage 7314 a, and radialpassages, 7318 a, 7318 b, and 7318 c, fluidicly coupled to thelongitudinal passage 7314 b, and includes a front end face 7320, a rearend face 7322, and a tapered external expansion surface 7324 includingspaced apart external grooves, 7324 a, 7324 b, and 7324 c, that arefluidicly coupled to the radial passages, 7314 a, 7316 a, 7314 b, 7316b, 7314 c, and 7316 c, respectively. A tubular member 7328 that definesa longitudinal passage 7328 a and radial passages, 7328 b and 7328 c,that are fluidicly coupled to the internal annular recess 7308 of theexpansion cone 7302, is received within, mates with, and is coupled tothe centrally positioned longitudinal passage 7306 of the expansioncone. A tubular piston 7340 defines a passageway 7340 a that receives,mates with and is slidably coupled to the tubular member 7328 and isreceived within, mates with and is slidably coupled to internal annularrecess 7332, of the expansion cone.

In an exemplary embodiment, during operation of the system 7300, theexpansion cone 7302 is positioned within, and displaced relative to, anexpandable tubular member 7330 thereby radially expanding andplastically deforming the expandable tubular member. In an exemplaryembodiment, the expansion cone 7302 is displaced relative to theexpandable tubular member 7330 by injecting a pressurized fluidicmaterial 7332 into and through the passage 7328 a of the tubular member7328. As a result, the expansion cone 7302 is displaced in a direction7333 relative to the expandable tubular member 7330. In an exemplaryembodiment, the fluidic material 7332 includes one or more lubricantmaterials suitable for lubricating the interface between the expansioncone 7302 and the expandable tubular member 7330 during the radialexpansion process. In particular, in an exemplary embodiment, thefluidic material 7332 is conveyed through the radial passages, 7328 band 7328 c, of the tubular member 7328, into an annular chamber 7336defined between the external annular recess 7310 of the expansion cone7302 and the expandable tubular member 7330 above tubular piston 7340.In an exemplary embodiment, a second fluidic material 7344 may be housedin the annular chamber 7336 below tubular piston 7342. In an exemplaryembodiment, the second fluidic material 7344 includes one or morelubricant materials suitable for lubricating the interface between theexpansion cone 7302 and the expandable tubular member 7330 during theradial expansion process. If the operating pressure of the fluidicmaterial 7332 exceeds a predetermined value, which may vary as afunction of the operating characteristics the tubular piston 7340, thefluidic material 7344 is then conveyed through the radial passages, 7328b and 7328 c, into an annular chamber 7336 defined between the externalannular recess 7310 of the expansion cone 7302 and the expandabletubular member 7330. In particular, if the operating pressure of thefluidic material 7332 exceeds a predetermined value, the tubular piston7340 is displaced within the annular chamber 7336 thereby pumping thepressurized fluidic material 7344 into the external grooves, 7324 a,7324 b, and 7324 c, through the longitudinal passages, 7314 a and 7314b, and the radial passages, 7316 a, 7316 b, 7316 c, 7318 a, 7318 b, and7318 c, into the interface between the expansion cone 7302 and theexpandable tubular member 7330.

In an exemplary embodiment, the rate of injection of the fluidicmaterial 7344 into the external grooves, 7324 a, 7324 b, and 7324 c,depends on the operating pressure of the fluidic material 7232 and theoperating characteristics of the tubular piston 7340. The tubular piston7340 pumps second fluidic material 7344 when the input pressure of thefluidic material 7332 exceeds a predetermined pressure limit, which maybe a factor of diameter of the tubular member 7330 the length of thetubular member 7330 and the desired amount of lubricant to be dispensed.In this manner, during the radial expansion process, the fluidicmaterial 7344 may be controllably injected and pumped into the interfacebetween the tapered external expansion surface 7324 of the expansioncone 7302 and the expandable tubular member 7330 continuously during theradial expansion and plastic deformation of the tubular member. In anexemplary embodiment, the fluidic material 7332 may be injected into theexternal grooves, 7324 a, 7324 b, and 7324 c only when required, or asdesired. Thus, the trailing edge portion of the interface between thetapered external expansion surface 7324 of the expansion cone 7302 andthe expandable tubular member 7330 may be provided with an increasedsupply of lubricant, thereby reducing the amount of force required toradially expand and plastically deform the expandable tubular member.

In an exemplary embodiment, the second fluidic material 7344 in theannular chamber 7336 below tubular piston 7340 may be preloaded intoexpansion cone 7300 prior to being used to expand tubular member 7330.Alternatively, the lubricant may be replenished by a lubrication sourcelocated in a remote location from expansion cone 7300.

Referring to FIG. 65, an embodiment of a system 7400 for lubricating theinterface between an expansion cone and a tubular member during theexpansion process will now be described. As illustrated in FIG. 65, anexpansion cone 7402 includes a body 7404 that defines a centrallypositioned longitudinal passage 7406, an internal annular recess 7408,an external annular recess 7410, longitudinal passages, 7412 a and 7412b, fluidicly coupled between the internal and external annular recesses,longitudinal passages, 7414 a and 7414 b, fluidicly coupled to theexternal annular recess, radial passages, 7416 a, 7416 b, and 7416 c,fluidicly coupled to the longitudinal passage 7414 a, and radialpassages, 7418 a, 7418 b, and 7418 c, fluidicly coupled to thelongitudinal passage 7414 b, and includes a front end face 7420, a rearend face 7422, and a tapered external expansion surface 7424 includingspaced apart external grooves, 7424 a, 7424 b, and 7424 c, that arefluidicly coupled to the radial passages, 7414 a, 7416 a, 7414 b, 7416b, 7414 c, and 7416 c, respectively. Spring-biased check valves, 7426 aand 7426 b, are received within, mate with, and are operably coupled to,the longitudinal passages, 7414 a and 7414 b, respectively, forcontrolling the flow of fluidic materials therethrough. A tubular member7428 that defines a longitudinal passage 7428 a and radial passages,7428 b and 7428 c, that are fluidicly coupled to the internal annularrecess 7408 of the expansion cone 7402 is received within, mates with,and is coupled to the centrally positioned longitudinal passage 7406 ofthe expansion cone. A tubular piston 7440 defines a passageway 7440 athat receives, mates with and is slidably coupled to the tubular member7428 and is received within, mates with and is slidably coupled tointernal annular recess 7432 of the expansion cone 7400.

In an exemplary embodiment, during operation of the system 7400, theexpansion cone 7402 is positioned within, and displaced relative to, anexpandable tubular member 7430 thereby radially expanding andplastically deforming the expandable tubular member. In an exemplaryembodiment, the expansion cone 7402 is displaced relative to theexpandable tubular member 7430 by injecting a pressurized fluidicmaterial 7432 into and through the passage 7428 a of the tubular member7428. As a result, the expansion cone 7402 is displaced in a direction7433 relative to the expandable tubular member 7430. In an exemplaryembodiment, the fluidic material 7432 includes one or more lubricantmaterials suitable for lubricating the interface between the expansioncone 7402 and the expandable tubular member 7430 during the radialexpansion process. In particular, in an exemplary embodiment, thefluidic material 7432 is conveyed through the radial passages, 7428 band 7428 c, of the tubular member 7428 into a annular chamber 7434defined between the internal annular recess 7408 of the expansion cone7402 and the tubular member 7428. In an exemplary embodiment, a secondfluidic material 7444 may be housed in the annular chamber 7434 belowtubular piston 7442 and in an annular chamber 7436 defined between theexternal annular recess 7410 of the expansion cone 7402 and theexpandable tubular member 7430. In an exemplary embodiment, the fluidicmaterial 7444 includes one or more lubricant materials suitable forlubricating the interface between the expansion cone 7402 and theexpandable tubular member 7430 during the radial expansion process. Ifthe operating pressure of the fluidic material 7432 exceeds apredetermined value, which will vary as a function of the operatingcharacteristics of the check valves, 7426 a and 7426 b, and tubularpiston 7440, the tubular piston is displaced within annular chamber7434, thereby pumping the second fluidic material through thelongitudinal passages, 7412 a and 7412 b, into the annular chamber 7436.The pressurized fluidic material 7444 is then conveyed into the externalgrooves, 7424 a, 7424 b, and 7424 c, through the longitudinal passages,7414 a and 7414 b, and the radial passages, 7416 a, 7416 b, 7416 c, 7418a, 7418 b, and 7418 c, into the interface between the expansion cone7402 and the expandable tubular member 7430.

In an exemplary embodiment, the rate of injection of the fluidicmaterial 7444 into the external grooves, 7424 a, 7424 b, and 7424 c,depends on the operating pressure of the fluidic material and theoperating characteristics of the spring-biased check valves, 7426 a and7426 b, and tubular piston 7440. In this manner, during the radialexpansion process, the fluidic material 7444 may be controllablyinjected and metered into the interface between the tapered externalexpansion surface 7424 of the expansion cone 7402 and the expandabletubular member 7430 continuously during the radial expansion and plasticdeformation of the tubular member. In an exemplary embodiment, thefluidic material 7444 may be injected into the external grooves, 7424 a,7424 b, and 7424 c only when required, or as desired. Thus, the trailingedge portion of the interface between the tapered external expansionsurface 7424 of the expansion cone 7402 and the expandable tubularmember 7430 may be provided with an increased supply of lubricant,thereby reducing the amount of force required to radially expand andplastically deform the expandable tubular member.

In an embodiment, valves 7426 a and 7426 b, permits lubricant flow whenthe input pressure of the fluidic material 7432 exceeds a predeterminedpressure limit, which may be a factor of diameter of the tubular member,the length of the tubular member and the desired amount of lubricant tobe dispensed. In an embodiment, tubular piston 7440 pumps the fluidicmaterial 7444 into the annular chamber 7736, based on the input pressureof the fluidic material 7432, such as, for example, when the inputpressure of the fluidic material 7444 exceeds a predetermined pressurelimit, which may be a factor of diameter of the tubular member 7430, thelength of the tubular member 7430 and the desired amount of lubricant tobe injected.

In an exemplary embodiment, the second fluidic material 7444 in annularchambers, 7434 and 7436 below tubular piston 7440 may be preloaded intoexpansion cone 7400 prior to being used to expand tubular member 7402.Alternatively, the lubricant may be replenished by a lubrication sourcelocated in a remote location from expansion cone 7400.

In an alternate embodiment, the tubular piston 7440 and spring-biasedcheck valves, 7426 a and 7426 b, may be omitted, and/or used incombination with other types of flow metering devices such as, forexample, passive flow control devices, active flow control devices,fixed orifices, and/or variable orifices.

Referring to FIG. 66, an embodiment of a system 7500 for lubricating theinterface between an expansion cone and a tubular member during theexpansion process will now be described. As illustrated in FIG. 66, anexpansion cone 7502 includes a body 7504 that defines a centrallypositioned longitudinal passage 7506, an internal annular recess 7508,an external annular recess 7510, longitudinal passages, 7512 a and 7512b, fluidicly coupled between the internal and external annular recesses,longitudinal passages, 7514 a and 7514 b, fluidicly coupled to theexternal annular recess, radial passages, 7516 a, 7516 b, and 7516 c,fluidicly coupled to the longitudinal passage 7514 a, and radialpassages, 7518 a, 7518 b, and 7518 c, fluidicly coupled to thelongitudinal passage 7514 b, and includes a front end face 7520, a rearend face 7522, and a tapered external expansion surface 7524 includingspaced apart external grooves, 7524 a, 7524 b, and 7524 c, that arefluidicly coupled to the radial passages, 7514 a, 7516 a, 7514 b, 7516b, 7514 c, and 7516 c, respectively. Spring-biased check valves, 7526 aand 7526 b, are received within, mate with, and are operably coupled to,the longitudinal passages, 7514 a and 7514 b, respectively, forcontrolling the flow of fluidic materials therethrough. A tubular member7528 that defines a longitudinal passage 7528 a and radial passages,7528 b and 7528 c, that are fluidicly coupled to the internal annularrecess 7508 of the expansion cone 7502 is received within, mates with,and is coupled to the centrally positioned longitudinal passage 7506 ofthe expansion cone. A conventional pressure enhancer 7550 is receivedwithin, mates with and is slidably coupled to external annular recess7510, of the expansion cone.

In an exemplary embodiment, during operation of the system 7500, theexpansion cone 7502 is positioned within, and displaced relative to, anexpandable tubular member 7530 thereby radially expanding andplastically deforming the expandable tubular member. In an exemplaryembodiment, the expansion cone 7502 is displaced relative to theexpandable tubular member 7530 by injecting a pressurized fluidicmaterial 7532 into and through the passage 7528 a of the tubular member7528. As a result, the expansion cone 7502 is displaced in a direction7533 relative to the expandable tubular member 7530. In an exemplaryembodiment, the fluidic material 7532 includes one or more lubricantmaterials suitable for lubricating the interface between the expansioncone 7502 and the expandable tubular member 7530 during the radialexpansion process. In particular, in an exemplary embodiment, thefluidic material 7532 is conveyed through the radial passages, 7528 band 7528 c, of the tubular member 7528 into a annular chamber 7534defined between the internal annular recess 7508 of the expansion cone7502 and the tubular member 7528. The pressure enhancer 7550 increasesthe pressure on the fluidic material. If the operating pressure of thefluidic material 7532 exceeds a predetermined value, which will vary asa function of the operating characteristics of the check valves, 7526 aand 7526 b, the fluidic material is then conveyed through thelongitudinal passages, 7512 a and 7512 b, into an annular chamber 7536defined between the external annular recess 7510 of the expansion cone7502 and the expandable tubular member 7530. The pressurized fluidicmaterial 7532 is then conveyed into the external grooves, 7524 a, 7524b, and 7524 c, through the longitudinal passages, 7514 a and 7514 b, andthe radial passages, 7516 a, 7516 b, 7516 c, 7518 a, 7518 b, and 7518 c,into the interface between the expansion cone 7502 and the expandabletubular member 7530.

In an exemplary embodiment, the rate of injection of the fluidicmaterial 7532 into the external grooves, 7524 a, 7524 b, and 7524 c,depends on the operating pressure of the fluidic material and theoperating characteristics of the pressure enhancer 7550 and of thespring-biased check valves, 7526 a and 7526 b. In this manner, duringthe radial expansion process, the fluidic material 7532 may becontrollably injected and metered into the interface between the taperedexternal expansion surface 7524 of the expansion cone 7502 and theexpandable tubular member 7530 continuously during the radial expansionand plastic deformation of the tubular member. In an exemplaryembodiment, the fluidic material 7532 may be injected into the externalgrooves, 7524 a, 7524 b, and 7524 c only when required, or as desired.Thus, the trailing edge portion of the interface between the taperedexternal expansion surface 7524 of the expansion cone 7502 and theexpandable tubular member 7530 may be provided with an increased supplyof lubricant, thereby reducing the amount of force required to radiallyexpand and plastically deform the expandable tubular member.

In an alternate embodiment, the spring-biased check valves, 7526 a and7526 b, may be omitted, and/or used in combination with other types offlow metering devices such as, for example, passive flow controldevices, active flow control devices, fixed orifices, and/or variableorifices. In an alternate embodiment, the pressure enhancer 7550, whichany type of pressure enhancing device, such as, for example, a piston ora diaphragm, may be omitted, and/or used in combination with other typesof flow enhancing devices or pressure increasing devices, such as, forexample, passive flow control devices, active flow control devices,fixed orifices, and/or variable orifices, such as, for example, ahigh-pressure lubricator.

Referring to FIG. 67, an embodiment of a system 7600 for lubricating theinterface between an expansion cone and a tubular member during theexpansion process will now be described. As illustrated in FIG. 67, anexpansion cone 7602 includes a body 7604 that defines a centrallypositioned longitudinal passage 7606, an internal annular recess 7608,an external annular recess 7610, longitudinal passages, 7612 a and 7612b, fluidicly coupled between the internal and external annular recesses,longitudinal passages, 7614 a and 7614 b, fluidicly coupled to theexternal annular recess, radial passages, 7616 a, 7616 b, and 7616 c,fluidicly coupled to the longitudinal passage 7614 a, and radialpassages, 7618 a, 7618 b, and 7618 c, fluidicly coupled to thelongitudinal passage 7614 b, and includes a front end face 7620, a rearend face 7622, and a tapered external expansion surface 7624 includingspaced apart external grooves, 7624 a, 7624 b, and 7624 c, that arefluidicly coupled to the radial passages, 7614 a, 7616 a, 7614 b, 7616b, 7614 c, and 7616 c, respectively. Spring-biased check valves, 7626 aand 7626 b, are received within, mate with, and are operably coupled to,the longitudinal passages, 7614 a and 7614 b, respectively, forcontrolling the flow of fluidic materials therethrough. A tubular member7628 that defines a longitudinal passage 7628 a and radial passages,7628 b and 7628 c, that are fluidicly coupled to the internal annularrecess 7608 of the expansion cone 7602 is received within, mates with,and is coupled to the centrally positioned longitudinal passage 7606 ofthe expansion cone. A tubular piston 7640 defines a passageway 7642 thatreceives, mates with and is slidably coupled to the tubular member 7628and is received within, mates with and is slidably coupled to internalannular recess 7632, of the expansion cone. A conventional pressureenhancer 7650 is received within, mates with and is slidably coupled toexternal annular recess 7610, of the expansion cone 7630.

In an exemplary embodiment, during operation of the system 7600, theexpansion cone 7602 is positioned within, and displaced relative to, anexpandable tubular member 7630 thereby radially expanding andplastically deforming the expandable tubular member. In an exemplaryembodiment, the expansion cone 7602 is displaced relative to theexpandable tubular member 7630 by injecting a pressurized fluidicmaterial 7632 into and through the passage 7628 a of the tubular member7628. As a result, the expansion cone 7602 is displaced in a direction7633 relative to the expandable tubular member 7630. In an exemplaryembodiment, the fluidic material 7632 includes one or more lubricantmaterials suitable for lubricating the interface between the expansioncone 7602 and the expandable tubular member 7630 during the radialexpansion process. In particular, in an exemplary embodiment, thefluidic material 7632 is conveyed through the radial passages, 7628 band 7628 c, of the tubular member 7628 into a annular chamber 7634defined between the internal annular recess 7608 of the expansion cone7602 and the tubular member 7628. In an exemplary embodiment, a secondfluidic material 7644 may be housed in the annular chamber 7634 belowtubular piston 7642 and in an annular chamber 7636 defined between theexternal annular recess 7610 of the expansion cone 7602 and theexpandable tubular member 7630. In an exemplary embodiment, the fluidicmaterial 7644 includes one or more lubricant materials suitable forlubricating the interface between the expansion cone 7602 and theexpandable tubular member 7630 during the radial expansion process. Ifthe operating pressure of the fluidic material 7632 exceeds apredetermined value, which will vary as a function of the operatingcharacteristics of the check valves, 7626 a and 7626 b, and tubularpiston 7640, the tubular piston is displaced within annular chamber7634, thereby pumping the second fluidic material through thelongitudinal passages, 7612 a and 7612 b, into the annular chamber 7636.The pressure enhancer 7650 increases the pressure on the second fluidicmaterial 7644. The pressurized fluidic material 7644 is then conveyedinto the external grooves, 7624 a, 7624 b, and 7624 c, through thelongitudinal passages, 7614 a and 7614 b, and the radial passages, 7616a, 7616 b, 7616 c, 7618 a, 7618 b, and 7618 c, into the interfacebetween the expansion cone 7602 and the expandable tubular member 7630.

In an exemplary embodiment, the rate of injection of the fluidicmaterial 7644 into the external grooves, 7624 a, 7624 b, and 7624 c,depends on the operating pressure of the fluidic material and theoperating characteristics of the spring-biased check valves, 7626 a and7626 b, tubular piston 7640 and pressure enhancer 7650. In this manner,during the radial expansion process, the fluidic material 7644 may becontrollably injected and metered into the interface between the taperedexternal expansion surface 7624 of the expansion cone 7602 and theexpandable tubular member 7630 continuously during the radial expansionand plastic deformation of the tubular member. In an exemplaryembodiment, the fluidic material 7644 may be injected into the externalgrooves, 7624 a, 7624 b, and 7624 c only when required, or as desired.Thus, the trailing edge portion of the interface between the taperedexternal expansion surface 7624 of the expansion cone 7602 and theexpandable tubular member 7630 may be provided with an increased supplyof lubricant, thereby reducing the amount of force required to radiallyexpand and plastically deform the expandable tubular member.

In an embodiment, valves 7626 a and 7626 b, permits lubricant flow whenthe input pressure of the fluidic material 7632 exceeds a predeterminedpressure limit, which may be a factor of diameter of the tubular member,the length of the tubular member and the desired amount of lubricant tobe dispensed. In an embodiment, tubular piston 7640 pumps the fluidicmaterial 7644 into the annular chamber 7636, based on the input pressureof the fluidic material 7632, such as, for example, when the inputpressure of the fluidic material 7644 exceeds a predetermined pressurelimit, which may be a factor of diameter of the tubular member 7630, thelength of the tubular member-7630 and the desired amount of lubricant tobe injected.

In an exemplary embodiment, the second fluidic material 7644 in anannular chamber 7636 below tubular piston 7640 may be preloaded intoexpansion cone 7600 prior to being used to expand tubular member 7602.Alternatively, the lubricant may be replenished by a lubrication sourcelocated in a remote location from expansion cone 7600.

In an alternate embodiment, the tubular piston 7640 and spring-biasedcheck valves, 7626 a and 7626 b, may be omitted, and/or used incombination with other types of flow metering devices such as, forexample, passive flow control devices, active flow control devices,fixed orifices, and/or variable orifices. In an alternate embodiment,the pressure enhancer 7550, which any type of pressure enhancing device,such as, for example, a piston or a diaphragm, may be omitted, and/orused in combination with other types of flow enhancing devices orpressure increasing devices, such as, for example, passive flow controldevices, active flow control devices, fixed orifices, and/or variableorifices, such as, for example, a high-pressure lubricator.

Referring to FIG. 68, an embodiment of a system 7700 for lubricating theinterface between an expansion cone and a tubular member during theexpansion process will now be described. As illustrated in FIG. 68, anexpansion cone 7702 includes a body 7704 that defines a centrallypositioned longitudinal passage 7706, an internal annular recess 7708,an internal annular recess 7709, an external annular recess 7710,longitudinal passages, 7712 a and 7712 b, fluidicly coupled between theinternal and external annular recesses, longitudinal passages, 7714 aand 7714 b, fluidicly coupled to the external annular recess, radialpassages, 7716 a, 7716 b, and 7716 c, fluidicly coupled to thelongitudinal passage 7714 a, and radial passages, 7718 a, 7718 b, and7718 c, fluidicly coupled to the longitudinal passage 7714 b, andincludes a front end face 7720, a rear end face 7722, and a taperedexternal expansion surface 7724 including spaced apart external grooves,7724 a, 7724 b, and 7724 c, that are fluidicly coupled to the radialpassages, 7714 a, 7716 a, 7714 b, 7716 b, 7714 c, and 7716 c,respectively. Spring-biased check valves, 7726 a and 7726 b, arereceived within, mate with, and are operably coupled to, thelongitudinal passages, 7714 a and 7714 b, respectively, for controllingthe flow of fluidic materials therethrough. A tubular member 7728 thatdefines a longitudinal passage 7728 a and radial passages, 7728 b and7728 c, that are fluidicly coupled to the internal annular recess 7708of the expansion cone 7702 is received within, mates with, and iscoupled to the centrally positioned longitudinal passage 7706 of theexpansion cone. A tubular piston 7740 defines a passageway 7740 a thatreceives, mates with and is slidably coupled to the tubular member 7728and is received within, mates with and is slidably coupled to internalannular recess 7732, of the expansion cone. A capacitor bank 7750 isreceived within the internal annular chamber 7709 and is electricallycoupled to power source 7760 through connectors 7756. Electrodes 7754 aand 7754 b are received within external annular recess 7732 and areelectrically coupled to capacitor bank 7750 through connectors 7758.

In an exemplary embodiment, during operation of the system 7700, theexpansion cone 7702 is positioned within, and displaced relative to, anexpandable tubular member 7730 thereby radially expanding andplastically deforming the expandable tubular member. In an exemplaryembodiment, the expansion cone 7702 is displaced relative to theexpandable tubular member 7730 by injecting a pressurized fluidicmaterial 7732 into and through the passage 7728 a of the tubular member7728. As a result, the expansion cone 7702 is displaced in a direction7733 relative to the expandable tubular member 7730. In an exemplaryembodiment, the fluidic material 7732 includes one or more lubricantmaterials suitable for lubricating the interface between the expansioncone 7702 and the expandable tubular member 7730 during the radialexpansion process. In particular, in an exemplary embodiment, thefluidic material 7732 is conveyed through the radial passages, 7728 band 7728 c, of the tubular member 7728 into a annular chamber 7734defined between the internal annular recess 7708 of the expansion cone7702 and the tubular member 7728. In an exemplary embodiment, a secondfluidic material 7744 may be housed in the annular chamber 7734 belowtubular piston 7742 and in an annular chamber 7736 defined between theexternal annular recess 7710 of the expansion cone 7702 and theexpandable tubular member 7730. In an exemplary embodiment, the fluidicmaterial 7744 includes one or more lubricant materials suitable forlubricating the interface between the expansion cone 7702 and theexpandable tubular member 7730 during the radial expansion process. Ifthe operating pressure of the fluidic material 7732 exceeds apredetermined value, which will vary as a function of the operatingcharacteristics of the check valves, 7726 a and 7726 b, and tubularpiston 7740, the tubular piston is displaced within annular chamber7734, thereby pumping the second fluidic material through thelongitudinal passages, 7712 a and 7712 b, into the annular chamber 7736.The pressurized fluidic material 7744 is then conveyed into the externalgrooves, 7724 a, 7724 b, and 7724 c, through the longitudinal passages,7714 a and 7714 b, and the radial passages, 7716 a, 7716 b, 7716 c, 7718a, 7718 b, and 7718 c, into the interface between the expansion cone7702 and the expandable tubular member 7730. In an embodiment, thepressure on the fluidic material 7744 in annular recess 7736 may beincreased by the introduction of an electric pulse into the fluidicmaterial 7744 through electrodes, 7754 a and 7754 b by the dischargingthe capacitor bank 7750 to trigger a high-pressure gaseous expansionwithin the lubricant in external annular recess 7732 by means of anelectric discharge.

In an exemplary embodiment, the rate of injection of the fluidicmaterial 7744 into the external grooves, 7724 a, 7724 b, and 7724 c,depends on the operating pressure of the fluidic material and theoperating characteristics of the spring-biased check valves, 7726 a and7726 b, and tubular piston 7740. In this manner, during the radialexpansion process, the fluidic material 7744 may be controllablyinjected and metered into the interface between the tapered externalexpansion surface 7724 of the expansion cone 7702 and the expandabletubular member 7730 continuously during the radial expansion and plasticdeformation of the tubular member. In an exemplary embodiment, thefluidic material 7744 may be injected into the external grooves, 7724 a,7724 b, and 7724 c only when required, or as desired. Thus, the trailingedge portion of the interface between the tapered external expansionsurface 7724 of the expansion cone 7702 and the expandable tubularmember 7730 may be provided with an increased supply of lubricant,thereby reducing the amount of force required to radially expand andplastically deform the expandable tubular member.

In an embodiment, valves 7726 a and 7726 b, permits lubricant flow whenthe input pressure of the fluidic material 7732 exceeds a predeterminedpressure limit, which may be a factor of diameter of the tubular member,the length of the tubular member and the desired amount of lubricant tobe dispensed. In an embodiment, tubular piston 7740 pumps the fluidicmaterial 7744 into the annular chamber 7736, based on the input pressureof the fluidic material 7732, such as, for example, when the inputpressure of the fluidic material 7744 exceeds a predetermined pressurelimit, which may be a factor of diameter of the tubular member 7730, thelength of the tubular member 7730 and the desired amount of lubricant tobe injected.

In an exemplary embodiment, the second fluidic material 7744 in anannular chamber 7736 below tubular piston 7740 may be preloaded intoexpansion cone 7700 prior to being used to expand tubular member 7702.Alternatively, the lubricant may be replenished by a lubrication sourcelocated in a remote location from expansion cone 7700.

In an alternate embodiment, the tubular piston 7740 and spring-biasedcheck valves, 7726 a and 7726 b, may be omitted, and/or used incombination with other types of flow metering devices such as, forexample, passive flow control devices, active flow control devices,fixed orifices, and/or variable orifices.

In an exemplary embodiment, the introduction of electrodes 7754 a and7754 b that are electrically coupled via connectors 7758 to bank ofcapacitor 7750 to trigger a high-pressure gaseous expansion within anenclosed volume of lubricant in annular chamber 7736 when bank ofcapacitors 7750 discharge, which in turn, may increase the lubricantpressure. The discharge expansion may create a pressure impulse allowingmore lubricant to flow between the expansion cone 7700 and tubularmember 7730, thereby reducing the friction. The expansion may create apressure impulse in annular recess 7736 of approximately 15 ksi,allowing more lubricant to flow between expansion cone 7700 and tubularmember 7702 and thereby reducing the friction, which may reduce theworking pressure behind the expansion cone 7700.

A discharge may occur between electrodes 7754 a and 7754 b in thelubricant stored in external annular recess 7732 that acts as adielectric when capacitor bank 7750 discharge current through connectors7756 to electrodes 7754 a and 7754 b. When the lubricant dielectricbetween the electrodes 7754 a and 7754 b breaks down, a high temperaturearc is created which vaporizes some of the dielectric. Due to theincompressibility of fluids, the vaporization may create a pulse ofpressure, which complements the existing fluid pressure.

The following three properties may be considered when determining theproperties of a system for lubricating the interface between anexpansion cone and a tubular member implementing a mechanism to triggera high-pressure gaseous expansion: thermodynamic properties, electricproperties, and deformation properties of the tubular member during theexpansion process.

Regarding thermodynamic properties, due to the non-ideal nature of avaporized dielectric medium, the following equations may be utilized todetermining the properties of a system for lubricating the interfacebetween expansion cone 7700 and a tubular member 7702 during theexpansion process implementing a mechanism to trigger a high-pressuregaseous expansion. Van der Waals equation may be manipulated to expresspressure as a function of the ratio of dielectric medium density,average molar mass, and the dielectric's boiling point as follows:${\left\lbrack {P + {a\left( \frac{n}{V} \right)}^{2}} \right\rbrack\left( {V - {nb}} \right)} = {nRT}$where:

P—Pressure [psi]

V—Volume of Vaporized Lubricant

T—Temperature [K]

n—Moles of Lubricant [mols]

R—1.206 [L-psi/K-mol]

a—Experimental Proportionality Constant

b—Experimental Constant Relating to Molecular Volume$P = {\frac{{RT}_{b}}{\left( \frac{M}{\rho} \right) - b} - {a\left( \frac{\rho}{M} \right)}^{2}}$where:

P—Pressure [psi]

T_(b)—Lubricant's Boiling Point [° K.]

M—Av. Lubricant Molar Mass

ρ—Lubricant Density

R—1.206 [L-psi/K-mol]

a—Experimental Proportionality Constant

b—Experimental Constant Relating to Molecular Volume

Since the volume of the external annular recess 7732 is not welldefined, the following constraints may be used. It is assumed that thevaporization takes place at about the boiling point of the dielectric,because the addition of the heat of vaporization does not change thetemperature. However, increases beyond this temperature may have nonegative effect on vaporization. Furthermore, there is no common directmathematic relationship between the discharge energy and the pressurecreated by the vaporization. Molar mass of the dielectric may need to becalculated experimentally or mathematically if all the components of thedielectric medium are known. The constants ‘a’ and ‘b’ may beexperimentally determined or may be available in engineering tablesbased on the choice of lubricant.

The effective discharge energy (E_(effective)) of back of capacitor 7750should be greater than the energy required to vaporize ‘m’ grams of thelubricant as exhibited in the following equation:E _(effective)=½k _(e) CV _(b) ² >mL _(v) +mL _(s) T  (13)T=T _(b) −T _(i) [K]  (14)where:

E_(eff.)—Effective Lubricant Energy [J]

k_(e)—Energy Efficiency Factor

C—Capacitance

V_(b)—Breakdown Voltage

m—Mass of Vaporized Lubricant

L_(v)—Heat of Vaporization [J/gm]

L_(s)—Specific Heat [J/gm-K]

T_(b)—Lubricant's Boiling Point [K]

T_(i)—Dielectric Initial Temperature [K] T−T_(b)−T_(i) [K]

The effective discharge energy (E_(effective)) of back of capacitor 7750is proportionately related to the calculated discharge energy of back ofcapacitor 7750 by an experimentally determined an “energy efficiencyfactor”. The mass ‘m’ of vaporized lubricant will depend on the geometryof the electrodes and of the discharge volume.

Regarding electric properties, the discharge of electricity takes placewhen the potential across the electrodes equals the breakdown voltage.Breakdown voltage for two electrodes 7754 a and 7754 b can be calculatedfrom the lubricant's dielectric strength using the following equations:V _(b) =dE _(ds)  (15)where:

V_(b)—Breakdown Voltage

d—Distance Between Electrodes [mm]

E_(ds)—Dielectric Strength [kV/mm]

In general, oils have high dielectric strengths, on the order of about10-50 kV/mm. In an exemplary embodiment, a dielectric strength on thelow end of that range may be desired.

An expression for the relation between current and total resistance isas follows: $\begin{matrix}{V_{b} = {{IR} > \sqrt{\frac{2{m\left( {L_{v} + {L_{s}T}} \right)}}{k_{e}C}}}} & (16)\end{matrix}$where:

V_(b)—Breakdown Voltage

I— Line Current

m—Mass of Vaporized Dielectric

R—System Resistance

L_(v)—Heat of Vaporization [J/gm]

L_(s)—Specific Heat [J/gm-K]

T—T_(b)−T_(i)[K]

k_(e)—Energy Efficiency Factor

C—CapacitanceR=R _(internal) +R _(design) +Z _(line)  (17)where:

R—System Resistance

R_(int.)—Internal Resistance

R_(design)—Design Resistance

Z_(line)—Line Impedance

The resistance consists of several components, internal resistance ofbank of capacitors 7752, resistance added by the designer, and lineimpedance. Line impedance may play an important role since the systemwill not be in steady state and may need to be determined empirically.

The equation for the effective discharge energy E_(effective) of bank ofcapacitors 7752 suggests that minimizing the specific heat and the heatof vaporization may result in lower required discharge energy. Syntheticoils, which generally have higher heats of vaporization, generally havefilm strengths exceeding 3000 psi. Mineral-based oils have filmstrengths of about 400 psi. However, neither synthetic oils nor mineralbased oils may be sufficient for the expected pressures of 10 ksi-15ksi. It seems that a hard lubricant with a higher tolerance forpressure, such as graphite or molybdenum disulfide, may work better.However, the heat of vaporization of a hard lubricant may besignificantly higher than that of a liquid lubricant. Also, theelectrodes 7754 a and 7754 b and the surrounding liquid dielectric maybe insulated to prevent any permanent dielectric breakdown in such ahard lubricants. The use of a system for lubricating the interfacebetween an expansion cone and a tubular member during the expansionprocess implementing a mechanism to trigger a high-pressure gaseousexpansion may be also advantageous because it allows more flexibility inthe choice of the dielectric medium.

An important aspect of the a system for lubricating the interfacebetween an expansion cone and a tubular member during the expansionprocess implementing a mechanism to trigger a high-pressure gaseousexpansion design is the frequency of the discharges. Assuming, for thepurpose of analysis that the breakdown voltage across the electrodes7754 a and 7754 b is reached at around t-RC sec, frequency can be easilyexpressed by thy following equation: $\begin{matrix}{\lambda = \frac{1}{RC}} & (18)\end{matrix}$where:

R—System Resistance

λ—Discharge Frequency [Hz]

C—Capacitance

Estimating that the frequency of the discharges will be at least 3 Hz,the lifetime rating of the capacitor bank 7750 should be as high.

Since the expansion cone may be used at considerable depths, it isdesirable that capacitor bank 7750 be located as close to the electrodes7754 a and 7754 b as possible. In one embodiment, it is anticipated thatany commercial capacitor for high-power pulsing applications that usescharging voltages in the tens of kV, can retain several kJ of energy,and is able to deliver current on the order of 100 kA may be used incapacitor bank 7750. In addition, the selected capacitor should be ableto tolerate significant voltage reversal. In an exemplary embodiment,high power capacitors, such as those manufactured by Passoni Villa thathave built in switches, may be used to achieve more control of thedischarge frequency.

In an exemplary embodiment, the following of manufacturers may supplycapacitors suitable for capacitor bank 7750, include the following:

Passoni Villa (www.passoni-villa.com (Capacitors));

Aerovox (www.aerovox.com (Capacitors));

Richardson Electronics (www.industrial.rell.com (Ignitrons));

Darrah Electric (www.darrahelectric.com (Power Semiconductors));

Magnet-Physik (www.magnet-physik.de (EMF Forming)) and

Magneform (www.magneform.com (EMF Forming)).

In an exemplary embodiment, capacitor bank 7750 may include onecapacitor or a plurality of capacitors.

In an exemplary embodiment, a solid-state amplifier located near thecapacitor bank 7750 may be utilized instead of a high-voltagetransformer due to size considerations. Example manufacturers of suchdevices are as follows:

Richardson Electronics (www.industrial.rell.com (Ignitrons));

Darrah Electric (www.darrahelectric.com (Power Semiconductors));

Magnet-Physik (www.magnet-physik.de (EMF Forming)); and

Magneform (www.magneform.com (EMF Forming)).

Regarding the expandable tubular member deformation characteristics, thework done on tubular member 7702 by the shockwave created by theelectric discharge may be constrained to be less than the amount of workrequired to deform the tube. The work done on the tubular member 7702can be calculated using the tubular member 7702 material properties andits cylindrical geometry. The expression for specific work ofdeformation is as follows: $\begin{matrix}{a_{s} = {\frac{B}{1 + m_{m}}E^{({1 + m_{m}})}}} & (19)\end{matrix}$where:

a_(s)—Specific Work of Deformation

E—Deformation Intensity

B, m_(m)—Mechanical characteristics of tubular member 7702

The constant m_(m), true strain, is defined the following equation:$\begin{matrix}{m_{m} = {e_{n} = {\ln\left( {1 + \frac{\Delta\quad\ln}{l_{0}}} \right)}}} & (20)\end{matrix}$where:

m_(m)—True Strain

ΔI_(n)/I₀—Elongation

In an exemplary embodiment, ΔI_(n)/I₀ is the elongation of tubularmember 7702, such as for example, in the case of En-80 steel, withΔI_(n)/I₀=0.20, m_(m)=0.182.

The mechanical constant B is defined by the following equation.$\begin{matrix}{{B = {\frac{E^{m_{m}}}{e_{n}^{m_{m}}}\sigma_{b}}}{{where}\text{:}}{{E\text{-}\frac{r}{r_{0}}} - 1}{m_{m}\text{-}{True}\quad{Strain}}{{e_{n}\text{-}e_{n}} = m_{m}}{\sigma_{b}\text{-}{Yield}\quad{Strength}}} & (21)\end{matrix}$

For a cylindrical geometry such as that of tubular member 7702, E isdefined the following equation: $\begin{matrix}{E = {\frac{r}{r_{0}} - 1}} & (22)\end{matrix}$where:

E—Deformation Intensity

r₀—Original Radius

r—Final Radius

The radius referred to is the inner radius of the tubular member 7702.

The total work of deformation is a function of the specific work ofdeformation and the volume of the tubular member 7702 material deformed.The work done by the discharge on the tubular member must be no greaterthan the work required to expand the tubular member 7702 to its finalradius and is defined as follows:W _(D) <a _(s) V _(w)  (23)where:

a_(s)—Specific Work of Deformation

V_(w)—Volume of Deformed Material

W_(D)—Work Due to Discharge

An expression relating the maximum amount of work may be constructed byassuming a discharge volume of axial length β, and an outer radius r₀(the outer radius being equal to the inner radius of the unexpandedtubular member 7702). The final outer radius will be designated by r.The equation defining the volume of deformed material, V_(w), is asfollows:V _(w)=2β(r ² −r ₀ ²)  (24)where:

β—Axial Length of Discharge Volume

r—Final Radius

r₀—Original Radius

V_(w)—Volume of Deformed Material

In an exemplary embodiment, using the equations specified above for atubular member 7702 that expands from a 4.77″ inside diameter to a 5.68″inside diameter, hypothetically the deformation intensity (E) is 0.191,assuming that the axial length of discharge volume (β) is 0.04 m andproduces a volume of deformation material (V_(w)) of 0.005809 m³ andtrue strain (m_(m)) of 0.182. Note that the yield strength (σ_(b)) rangefor En-80 steel tubes is approximately 48.26×10⁷ N/m² (70 ksi) to65.50×10⁷ N/m² (95 ksi) and mechanical constant (B) is found to rangefrom 48.69×10⁷ N/m² to 66.08×10⁷ N/m². Therefore, the specific work(a_(s)) of deformation ranges from 5.82×10⁷ N/m² to 7.90×10⁷ N/m². Forthis particular volume and radial expansion, the amount of work requiredto expand the tubular member 7702 is on the order of 460 kJ to 340 kJ.Hence, the work done on the tubular member 7702 due to the discharge maynot exceed 340 kJ. However, the expected energy of the discharge is farlower. The pressure produced by the discharge may also be limited. Theyield strength of En-80 steel is 70-95 ksi. The pressure produced by thedischarge can therefore not exceed 70 ksi. Again, the expected maximumpressure due to the discharge will be approximately 15 ksi. However,should the stated constraints be exceeded, the results would beunpredictable, and control over the process could be lost.

In an exemplary embodiment, an apparatus for testing a system forlubricating the interface between an expansion cone and a tubular memberimplementing a mechanism to trigger a high-pressure gaseous expansionduring the expansion process may consider the following: (1) thedetermination of the specific capacitances of capacitor bank 7750,system resistances and impedances, and voltage required at power source7760 for implementation may be found experimentally; and (2) the processvalues for a given lubricant may be determined by utilizing a dischargevolume with piezoelectric sensors. Piezoelectric sensors are small, maywithstand extremely high pressures, and produce electric outputs thatare easily digitized and quantified for analysis. There are also severalpossible ways to regulate the power at power source 7760 in a testingapparatus, including for example, regulation of system resistance usingpotentiometers as an effective way to regulate the discharge power. Thecapacitor bank 7750 may also be designed to enable quick removal oraddition of capacitors. A digital oscilloscope may be connected to thetransmission line via a voltage divider to monitor system voltage.Finally, the current may be measured with a Rogowski coil, which usesthe Hall effect to measure high currents.

Referring to FIG. 69, an embodiment of a system 7800 for lubricating theinterface between an expansion cone and a tubular member during theexpansion process will now be described. As illustrated in FIG. 69, anexpansion cone 7802 includes a body 7804 that defines a centrallypositioned longitudinal passage 7806, an internal annular recess 7808,an external annular recess 7810, longitudinal passages, 7812 a and 7812b, fluidicly coupled between the internal and external annular recesses,longitudinal passages, 7814 a and 7814 b, fluidicly coupled to theexternal annular recess, radial passages, 7816 a, 7816 b, and 7816 c,fluidicly coupled to the longitudinal passage 7814 a, and radialpassages, 7818 a, 7818 b, and 7818 c, fluidicly coupled to thelongitudinal passage 7814 b, and includes a front end face 7820, a rearend face 7822, and a tapered external expansion surface 7824 includingspaced apart external grooves, 7824 a, 7824 b, and 7824 c, that arefluidicly coupled to the radial passages, 7814 a, 7816 a, 7814 b, 7816b, 7814 c, and 7816 c, respectively. Spring-biased check valves, 7826 aand 7826 b, are received within, mate with, and are operably coupled to,the longitudinal passages, 7814 a and 7814 b, respectively, forcontrolling the flow of fluidic materials therethrough. A tubular member7828 that defines a longitudinal passage 7828 a and radial passages,7828 b and 7828 c, that are fluidicly coupled to the internal annularrecess 7808 of the expansion cone 7802 is received within, mates with,and is coupled to the centrally positioned longitudinal passage 7806 ofthe expansion cone. A tubular piston 7840 defines a passageway 7840 athat receives, mates with and is slidably coupled to the tubular member7828 and is received within, mates with and is slidably coupled tointernal annular recess 7732, of the expansion cone. A magnetic coil7854 is received within external annular recess 7752 and is electricallycoupled to power source 7860 via connectors, 7756 a and 7756 b.

In an exemplary embodiment, during operation of the system 7800, theexpansion cone 7802 is positioned within, and displaced relative to, anexpandable tubular member 7830 thereby radially expanding andplastically deforming the expandable tubular member. In an exemplaryembodiment, the expansion cone 7802 is displaced relative to theexpandable tubular member 7830 by injecting a pressurized fluidicmaterial 7832 into and through the passage 7828 a of the tubular member7828. As a result, the expansion cone 7802 is displaced in a direction7833 relative to the expandable tubular member 7830. In an exemplaryembodiment, the fluidic material 7832 includes one or more lubricantmaterials suitable for lubricating the interface between the expansioncone 7802 and the expandable tubular member 7830 during the radialexpansion process. In particular, in an exemplary embodiment, thefluidic material 7832 is conveyed through the radial passages, 7828 band 7828 c, of the tubular member 7828 into a annular chamber 7834defined between the internal annular recess 7808 of the expansion cone7802 and the tubular member 7828. In an exemplary embodiment, a secondfluidic material 7844 may be housed in the annular chamber 7834 belowtubular piston 7842 and in an annular chamber 7836 defined between theexternal annular recess 7810 of the expansion cone 7802 and theexpandable tubular member 7830. In an exemplary embodiment, the fluidicmaterial 7844 includes one or more lubricant materials suitable forlubricating the interface between the expansion cone 7802 and theexpandable tubular member 7830 during the radial expansion process. Ifthe operating pressure of the fluidic material 7832 exceeds apredetermined value, which will vary as a function of the operatingcharacteristics of the check valves, 7826 a and 7826 b, and tubularpiston 7840, the tubular piston is displaced within annular chamber7834, thereby pumping the second fluidic material through thelongitudinal passages, 7812 a and 7812 b, into the annular chamber 7836.The pressurized fluidic material 7844 is then conveyed into the externalgrooves, 7824 a, 7824 b, and 7824 c, through the longitudinal passages,7814 a and 7814 b, and the radial passages, 7816 a, 7816 b, 7816 c, 7818a, 7818 b, and 7818 c, into the interface between the expansion cone7802 and the expandable tubular member 7830. In an embodiment, magneticcoil 7854 may trigger a high-pressure impulse in volume of fluidicmaterial in annular recess 7836 from a magnetic field created inmagnetic coil 7854 and thereby increase the pressure in the fluidicmaterial. The pressurized fluidic material 7844 is then conveyed intothe external grooves, 7824 a, 7824 b, and 7824 c, through thelongitudinal passages, 7814 a and 7814 b, and the radial passages, 7816a, 7816 b, 7816 c, 7818 a, 7818 b, and 7818 c, into the interfacebetween the expansion cone 7802 and the expandable tubular member 7830.

In an exemplary embodiment, the rate of injection of the fluidicmaterial 7844 into the external grooves, 7824 a, 7824 b, and 7824 c,depends on the operating pressure of the fluidic material and theoperating characteristics of the spring-biased check valves, 7826 a and7826 b, and tubular piston 7840. In this manner, during the radialexpansion process, the fluidic material 7844 may be controllablyinjected and metered into the interface between the tapered externalexpansion surface 7824 of the expansion cone 7802 and the expandabletubular member 7830 continuously during the radial expansion and plasticdeformation of the tubular member. In an exemplary embodiment, thefluidic material 7844 may be injected into the external grooves, 7824 a,7824 b, and 7824 c only when required, or as desired. Thus, the trailingedge portion of the interface between the tapered external expansionsurface 7824 of the expansion cone 7802 and the expandable tubularmember 7830 may be provided with an increased supply of lubricant,thereby reducing the amount of force required to radially expand andplastically deform the expandable tubular member.

In an embodiment, valves 7826 a and 7826 b, permits lubricant flow whenthe input pressure of the fluidic material 7832 exceeds a predeterminedpressure limit, which may be a factor of diameter of the tubular member,the length of the tubular member and the desired amount of lubricant tobe dispensed. In an embodiment, tubular piston 7840 pumps the fluidicmaterial 7844 into the annular chamber 7836, based on the input pressureof the fluidic material 7832, such as, for example, when the inputpressure of the fluidic material 7844 exceeds a predetermined pressurelimit, which may be a factor of diameter of the tubular member 7830, thelength of the tubular member 7830 and the desired amount of lubricant tobe injected.

In an exemplary embodiment, the second fluidic material 7844 in anannular chamber 7836 below tubular piston 7840 may be preloaded intoexpansion cone 7800 prior to being used to expand tubular member 7802.Alternatively, the lubricant may be replenished by a lubrication sourcelocated in a remote location from expansion cone 7800.

In an alternate embodiment, the tubular piston 7840 and spring-biasedcheck valves, 7826 a and 7826 b, may be omitted, and/or used incombination with other types of flow metering devices such as, forexample, passive flow control devices, active flow control devices,fixed orifices, and/or variable orifices.

In an exemplary embodiment, magnetic coil 7854 triggers a high-pressureimpulse in the lubricant in annular recess 7836 by means of a magneticfield created by in magnetic coil 7854 when current is generated bypower source 7860 and run through magnetic coil 7854. In an exemplaryembodiment, when current generated by power source 7860 is run throughmagnetic coil 7854 via cables 7856 a and 7856 b in the fluidic materials7844 in annular chamber 7836, a magnetic field is generated around themagnetic coils 7854 that may trigger a high-pressure gaseous expansionwithin an enclosed volume of fluidic materials 7844 by means offorce/impulse from a strong magnetic field. The expansion may create apressure, allowing more lubricant to flow between the expansion cone7800 and the tubular member 7830 and thereby reducing the friction andworking pressure behind the expansion cone 7800. In an exemplaryembodiment, cables, 7856 a and 7856 b may be used to provide power tothe magnetic coils 7854 that may generate the magnetic field.

Referring to FIG. 70, an embodiment of a system 7900 for lubricating theinterface between an expansion cone and a tubular member during theexpansion process will now be described. As illustrated in FIG. 70, anexpansion cone 7902 includes a body 7904 that defines a centrallypositioned longitudinal passage 7906, an internal annular recess 7908,an external annular recess 7910, longitudinal passages, 7912 a and 7912b, fluidicly coupled between the internal and external annular recesses,longitudinal passages, 7914 a and 7914 b, fluidicly coupled to theexternal annular recess, radial passages, 7916 a, 7916 b, and 7916 c,fluidicly coupled to the longitudinal passage 7914 a, radial passages,7917 a and 7917 b, fluidicly coupled to the longitudinal passage 7906and radial passage 7928 c and 7928 d, and includes a front end face7920, a rear end face 7922, and a tapered external expansion surface7924 including spaced apart external grooves, 7924 a, 7924 b, and 7924c, that are fluidicly coupled to the radial passages, 7914 a, 7916 a,7914 b, 7916 b, 7914 c, and 7916 c, respectively. Spring-biased checkvalves, 7926 a and 7926 b, are received within, mate with, and areoperably coupled to, the longitudinal passages, 7914 a and 7914 b,respectively, for controlling the flow of fluidic materialstherethrough. A tubular member 7928 that defines a longitudinal passage7928 a and radial passages, 7928 b and 7928 c, that are fluidiclycoupled to the internal annular recess 7908 of the expansion cone 7902is received within, mates with, and is coupled to the centrallypositioned longitudinal passage 7906 of the expansion cone. A tubularpiston 7940 defines a passageway 7940 a that receives, mates with and isslidably coupled to the tubular member 7928 and is received within,mates with and is slidably coupled to internal annular recess 7932, ofthe expansion cone.

In an exemplary embodiment, during operation of the system 7900, theexpansion cone 7902 is positioned within, and displaced relative to, anexpandable tubular member 7930 thereby radially expanding andplastically deforming the expandable tubular member. In an exemplaryembodiment, the expansion cone 7902 is displaced relative to theexpandable tubular member 7930 by injecting a pressurized fluidicmaterial 7932 into and through the passage 7928 a of the tubular member7928. As a result, the expansion cone 7902 is displaced in a direction7933 relative to the expandable tubular member 7930. In an exemplaryembodiment, the fluidic material 7932 includes one or more lubricantmaterials suitable for lubricating the interface between the expansioncone 7902 and the expandable tubular member 7930 during the radialexpansion process. In particular, in an exemplary embodiment, thefluidic material 7932 is conveyed through the radial passages, 7928 band 7928 c, of the tubular member 7928 into a annular chamber 7934defined between the internal annular recess 7908 of the expansion cone7902 and the tubular member 7928. In an exemplary embodiment, a secondfluidic material 7944 may be housed in the annular chamber 7934 belowtubular piston 7942 and in an annular chamber 7936 defined between theexternal annular recess 7910 of the expansion cone 7902 and theexpandable tubular member 7930. In an exemplary embodiment, the fluidicmaterial 7944 includes one or more lubricant materials suitable forlubricating the interface between the expansion cone 7902 and theexpandable tubular member 7930 during the radial expansion process. Ifthe operating pressure of the fluidic material 7932 exceeds apredetermined value, which will vary as a function of the operatingcharacteristics of the check valves, 7926 a and 7926 b, and tubularpiston 7940, the tubular piston is displaced within annular chamber7937, thereby pumping the second fluidic material through thelongitudinal passages, 7912 a and 7912 b, into the annular chamber 7936.The pressurized fluidic material 7944 is then conveyed into the externalgrooves, 7924 a, 7924 b, and 7924 c, through the longitudinal passages,7914 a and 7914 b, and the radial passages, 7916 a, 7916 b, 7916 c, 7918a, 7918 b, and 7918 c, into the interface between the expansion cone7902 and the expandable tubular member 7930. Similarly, in an exemplaryembodiment, the fluidic material 7932 is conveyed through the radialpassages, 7928 d and 7928 e, of the tubular member 7928 and throughradial passages, 7917 a and 7917 b, into a passageway 7952 definedbetween the expansion cone 7902 and the tubular member 7930.

In an exemplary embodiment, the rate of injection of the fluidicmaterial 7944 into the external grooves, 7924 a, 7924 b, and 7924 c,depends on the operating pressure of the fluidic material and theoperating characteristics of the spring-biased check valves, 7926 a and7926 b, and tubular piston 7940. In this manner, during the radialexpansion process, the fluidic material 7944 may be controllablyinjected and metered into the interface between the tapered externalexpansion surface 7924 of the expansion cone 7902 and the expandabletubular member 7930 continuously during the radial expansion and plasticdeformation of the tubular member. In an exemplary embodiment, thefluidic material 7944 may be injected into the external grooves, 7924 a,7924 b, and 7924 c only when required, or as desired. Thus, the trailingedge portion of the interface between the tapered external expansionsurface 7924 of the expansion cone 7902 and the expandable tubularmember 7930 may be provided with an increased supply of lubricant,thereby reducing the amount of force required to radially expand andplastically deform the expandable tubular member.

The rate of injection of fluidic material 7932 into passageway 7952between expansion cone 7900 and tubular member 7902 depends on the inputpressure of the fluidic material 7932. Since, the rate of injection ofthe second fluidic material 7944 into the external grooves, 7924 a, 7924b, and 7924 c, depends on the operating pressure of the fluidic materialand the operating characteristics of the spring-biased check valves,7926 a and 7926 b, and tubular piston 7940, the delivery of the fluidicmaterial 7930 into passageway 7952 may be at a different pressure thanthe pressure of the fluidic material 7932 injected into passageway 7952between expansion cone 7900 and tubular member 7902.

In an embodiment, valves 7926 a and 7926 b, permits lubricant flow whenthe input pressure of the fluidic material 7932 exceeds a predeterminedpressure limit, which may be a factor of diameter of the tubular member,the length of the tubular member and the desired amount of lubricant tobe dispensed. In an embodiment, tubular piston 7940 pumps the fluidicmaterial 7944 into the annular chamber 7936, based on the input pressureof the fluidic material 7932, such as, for example, when the inputpressure of the fluidic material 7944 exceeds a predetermined pressurelimit, which may be a factor of diameter of the tubular member 7930, thelength of the tubular member 7930 and the desired amount of lubricant tobe injected.

In an exemplary embodiment, the second fluidic material 7944 in anannular chamber 7936 below tubular piston 7940 may be preloaded intoexpansion cone 7900 prior to being used to expand tubular member 7902.Alternatively, the lubricant may be replenished by a lubrication sourcelocated in a remote location from expansion cone 7900.

In an alternate embodiment, the tubular piston 7940 and spring-biasedcheck valves, 7926 a and 7926 b, may be omitted, and/or used incombination with other types of flow metering devices such as, forexample, passive flow control devices, active flow control devices,fixed orifices, and/or variable orifices.

It is understood that variations may be made in the foregoing expansionlubricant delivery systems without departing from the scope of theinvention. For example, the teachings of the present illustrativeembodiments may be used to vary the expansion cone size, shape, andexternal and internal structure. Furthermore, the elements and teachingsof the various illustrative embodiments may be combined in whole or inpart in some or all of the illustrative embodiments. In addition, one ormore of the elements and teachings of the various illustrativeembodiments may be omitted, at least in part, and/or combined, at leastin part, with one or more of the other elements and teachings of thevarious illustrative embodiments.

For example, in an exemplary embodiment, valve may not be used in theexpansion cone. In another exemplary embodiment only one or a pluralityof lubricant reservoirs may be utilized in the expansion cone.

Lubricants

When selecting a lubricant for a system for lubricating the interfacebetween an expansion cone and a tubular member during the expansionprocess, the lubricant may be any media that may assist in reducing thefriction between the expansion cone and a tubular member, including anyfluidic material. Several factors may be considered, including thecoefficient of friction between the expansion cone and tubular member,the size and complexity of the expansion cone, and the lubricantinjection pressure, length of the tubular member and the amount oflubricant to be dispersed. The lubricant may include wet lubricantsand/or solid lubricants. It is expected that the lubricant typicallyneed to withstand at least 5000 psi of pressure.

In an exemplary embodiment, the lubricants for a system for lubricatingthe interface between an expansion cone and a tubular member during theexpansion process may include, conventional commercial lubricants(natural and synthetic), working hydraulic fluid mud currently used inexpandable tubular systems, and working hydraulic fluid mud blended withsolid lubricants to improve lubricity. In an exemplary embodiment, alithium based (non-synthetic) multipurpose grease combined with a solidlubricant may be used as the lubricant. In an exemplary embodiment, agrease lubricant for this application may be composed of a solidlubricant in a moderately high temperature resistant thickener. In anexemplary embodiment, the lubricant may have at least 10% Graphite or10% Molybdenum Disulfide in a thickener with a dropping point above350-400 F. In an exemplary embodiment, two lubricants, which meet therequirements state above, and their respective suppliers, are asfollows: Lubricant Name Manufacturer Composition Supplier 339-S DixonLube 30% Dixon Lubricants and Graphite Grease Graphite SpecialtyProducts, Asbury, New Jersey #3HT Bemol 15% The Rose Mill Moli-GreaseMolybdenum Company, East Harford, Connecticut

Exemplary embodiments of lubricants that may be used in a system forlubricating the weight percentages interface between an expansion coneand a tubular member may consist of the following component inindicated: Weight Component Percentage Characteristic Examples 164.25-90.89% Base oil A natural triglyceride oil which is, such as forexample, fish, animal or vegetable triglyceride oil, or mixturesthereof. The triglyceride oil is a vegetable triglyceride oil, such asfor example, sunflower seed oil, soybean oil, rapeseed oil canola oil,palm nut oil, palm oil, olive oil, rapeseed oil, canola oil, linseedoil, ground nut oil, soybean oil, cottonseed oil, sunflower seed oil,pumpkin seed oil, coconut oil, corn oil, castor oil, walnut oil andmixtures thereof. A natural or synthetic oil, which may be an esterwherein unsaturation as above triglycerides. The ester may be formed bya transesterification reaction of suitable monobasic and/or dibasicorganic acids with primary, secondary or tertiary alcohols. An exampleof such a naturally occurring ester is jojoba oil and such a syntheticester is lauryl oleate. The ester mentioned above may be formed by thereaction of unsaturated acids with polyhydric alcohols, such as forexample, neopentyl glycol, trimethylolylethane, trimethylolpropane orpentaerythritol. Examples of such a reaction product are pentaerythritolmonooleate, dioleate, trioleate, and the like. Example commerciallyavailable products are as follows: Canola oil from Cargil Inc (Agri-Pure60, Agri-Pure -85) or Lambent (Oleocal 102); and Sunflower oil (Lubrizol7631) 2  0.02-0.05% Metal Triazol and benzotriazol derivatives, such asfor deactivator example, tolyltriazol. Example commercially availableproducts are as follows: Tolyltriazole, from PMC Inc (Cobratec TT-100);and 1H-Benzotriazole-1 -Methanamine, N-N-bis (2-ethylhexyl)-methyl, fromCiba-Geigy Corp (Reomet 39) 3  0.5-3.0% Antioxidants Aromatic amineantioxidants and/or hindered phenolic antioxidants antioxidants, such asfor example, 2,6-bis (tert butyl-4-methylphenol, BHT). Examplecommercially available products are as follows: Octylated, ButylatedDiphenylamine Antioxidant from Ciba-Geigy Corp (Irganox L 57); 2,6-bis(1,1-dimethylethyl)-4-methyl- Phenol, from PMC, Inc (BHT); andBenzenepropanoic acid, 3,5-bis (1,1- demethylethyl)-4-hydroxy-,thiodi-2,1-ethanediyl ester, from Ciba-Geigy Corp (Irganox 1035); 4   4-12% Sulfurized Sulfurized vegetable or animal fatty oils, withnatural oils sulfur content 9%-21%, such as for example 13.5%-17.5%.Example commercially available products are as follows: Sulfurizedvegetable oils from Rhein Chemie Corporation (Additin RC-2515); andSulfurized Lard Oil from Ferro Corporation (HSL). 5    4-12% PhosphatePhosphoric acid esters with ethoxylated fatty ester (C12-C15) alcohols,preferably mixture of phosphoric acid ester with ethoxylated laurylalcohol and phosphoric acid ester with ethoxylated tridecyl alcohol.Example commercially available products are as follows: Phosphoric acidester with ethoxylated lauryl alcohol and phosphoric acid ester withethoxylated tridecyl alcohol from Houghton international (Houghton5653). 6  0.4-1.5% Phosphoric Phosphoric acid. acid An examplecommercially available product is phosphoric acid from Rhodia. 7 0.08-1.5% Viscosity Polyacrylates, polymethacrylates, modifiervinylpyrrolidone/methacrylate-copolymers, polyvinylpyrrolidones,polybutanes, olefin- copolymers, styrene/-acrylate-copolymers,polyethers, such as for example, styrene or butadiene - styrene polymer.An example commercially available product is Styrene Hydrocarbon Polymerfrom Lubrizol Corporation (Lubrizol ® 7440S). 8  0.1-0.5% Pour-pointPolymethacrylates, alkylated naphthalene depressant derivatives, such asfor example, alkyl ester copolymers. An example commercially availableproduct is Alkyl ester copolymer from Lubrizol Corporation (Lubrizol6662) 9  0.01-0.2% Defoamer Silicon based antifoam agent. An examplecommercially available product is Silicon based antifoam agent fromUltra Additives (Foam Ban 103) 10    0-5% Carboxylic Alkali,alkanolamine, alkyl amine or alkoxylated acid soaps amine salts of mono-or dibasic fatty acids, or mixture thereof. An example commerciallyavailable product is Soap formed in situ as a product of reactionbetween Tall Oil Fatty Acids (Sylvatal ® D30LR from Arizona ChemicalCo.) and triethanol amine (TEA 99 from Huntsman Corporation)The lubricant may optionally contain various other additives, or mixturethereof, in order to improve the basic properties. In an exemplaryembodiment, these further additives may include other antioxidants,metal deactivators, viscosity improvers, extreme-pressure additives,pour-point depressants, antifoam agents, dispersants, detergents,corrosion inhibitors, emulsifiers, demulsifiers and friction modifiers.

Exemplary experiments have shown that the lubricants identified in thetable below, H1, H2, H3, H4, H5, H6, and H7, identified by the specifiedcomponents in the weight percentages and the component manufacturesand/or distributors indicated may perform in a system for lubricatingthe interface between an expansion cone and a tubular member:Manufacture/ Example Lubricants Component Distributor H1 H2 H3 H4 H5 H6H7 1 Canola oil Agri-Pure 60 77.81%  64.25%  90.89%  68.71%  82.07% 80.68%    80.31%  2 Tolyltriazole Cobratec TT- 0.04%  0.05%  0.02%0.04%  0.03%  0.04%   0.04%  100 3 Aminic Irganox L 57 0   1% 0 0.5%0.5% 0 0 antioxidant Phenolic BHT 1.0%   2%  0.5%   1% 0.5% 1% 1.1%antioxidant 4 Sulfurized Additin RC-  10%  12%   4%  12%   9% vegetableoil 2515 Or Sulfurized HSL  10% 8% lard oil 5 Phosphoric Rhodofac RS  9%  12%   4%  10%   5% 9%   8% acid ester 410 + Rhodofac with PCethoxylated 100 lauryl alcohol and phosphoric acid ester withethoxylated tridecyl alcohol 6 Phosphoric Phosphoric   1% 1.5%  0.4%1.1% 0.5% 1% 0.8% acid acid 7 Styrene Lubrizol 0.8% 1.5% 0.08% 1.5% 0.1%0.1%   0.4% Hydrocarbon 7440S Polymer 8 Alkyl ester Lubrizol 6662 0.3%0.5%  0.1% 0.1% 0.2% 0.1%   0.3% copolymer 9 Silicon Foam Ban 0.05% 0.2% 0.01% 0.05 0.1% 0.08%   0.05%  based 103 antifoam agent 10Carboxylic Sylvatal ® 0   5% 0   5%   1% 0 0 acid soap D30LR + TEA 99

In addition introducing lubricants between an expansion cone and atubular member to reduce the coefficient of friction, the cone geometry,type of cone material, the cone texture (such as, for example, oilpocket on the surface of the cone) and coatings on the cone all affectthe overall coefficient of friction between the expansion cone and thetubular member material, coating and finish.

Expansion Cone Material

When selecting the material for an expansion cone to reduce thecoefficient of friction between an expansion cone and a tubular memberin a system for lubricating the interface between an expansion cone anda tubular member during the expansion process, several factors may beconsidered, including, among other things, the coefficient of frictionbetween the expansion cone and the tubular member, the size andcomplexity of the expansion cone, material hardness, compressivestrength, wear resistance, corrosion resistance, toughness, surfacefinish ability and coatings. In an exemplary embodiment, exampleexpansion cone materials include, high chrome, high carbon andmolybdenum based tool steels, as well as a few powdered materials.

In several exemplary embodiments, the following commercially availableexpansion cone materials may be used in a system for lubricating theinterface between an expansion cone and a tubular member: DC53, D2, D5,D7, M2, M4, CPM M4, 10V AND 3V. Referring to FIGS. 71 a, 71 b, 71 c, and71 d, the hardness, toughness, relative wear resistance and tempertemperature characteristics are shown for each of the cone materialslisted in the table above, respectively. FIG. 71 e shows some hardnesscharacteristics for some of the additional cone materials not listedabove. Example expansion cone material manufactures and/or distributorsare as follows:

-   -   1. International Mold Steel, Inc., of Florence, Ky. distributes        DC53 material; and    -   2. Crucible Materials Corporation of Syracuse, N.Y. distributes        D2, CPM M4, 10V AND 3V materials.        The characteristics of each material are specified below.

In an exemplary embodiment, an example of a DC53 material has thefollowing characteristics:

Higher hardness (62-63 HRc) than D2 after heat treatment;

Twice the toughness of D2 with superior wear resistance;

20% higher fatigue strength than D2;

Smaller primary carbides than D2 protect the die from chipping andcracking;

Secondary refining process (DLF) reduces impurities;

Machines and grinds up to 40% faster than D2; and

Less residual stress after wire EDMing.

In an exemplary embodiment, an example of a DC53 material has thefollowing Coefficient of Thermal Expansion (×10−6/C.°): Annealed ˜100°C. ˜200° ˜300° ˜400° ˜500° ˜600° ˜700° DC53 12.2 12.0 12.3 12.8 13.213.4 13.0

In an exemplary embodiment, an example of a DC53 material has thefollowing Coefficient of Thermal Conductivity (cal/cm·sec° C.): Quenchedand Tempered Room Temp. 100° C. 200° 300° 400° 500° 600° DC53 0.0570.060 0.064 0.064 0.065 0.062

In an exemplary embodiment, an example of a DC53 material has thefollowing physical data: Physical Characteristic Data Young's modulus(E) 21,700 Specific Gravity 7.87 Modulus of Rigidity (G) 8,480 Poisson'sRatio (v) 0.28

In an exemplary embodiment, an example of a DC53 material can behardened to 62-63 HRc in the same manner as D2, and when tempered athigh temperatures (520° to 530° C.), it assumes excellent properties.Even when tempered at lower temperatures (180° to 200° C.), itsperformance is equivalent to or better than that of D2. This improvedhardenability makes heat treatment easier and reduces hardness problemsdue to vacuum heat treatment, which uses gas cooling.

In an exemplary embodiment, an example of a DC53 material displayssuperior wear-resistance to D2 when tempered at high temperatures (520°C.) and equal wear resistance to D2 when tempered at low temperatures.High resistance to temper softening minimizes seizing and galling on thedie surface. DC53 is ideal for dies needing to maintain high surfacehardness against frictional heat between the die surface and the workedmaterials.

In an exemplary embodiment, an example of a D2 material is, AISI Type D2Tool Steel that is air-quenched from 1010° C. and tempered at 450° C.,which falls into the following subcategories: cold work steel; highcarbon steel; metal; and tool steel. The AISI Type D2 Tool Steel has thefollowing properties:

Mechanical Properties Metric English Comments—

-   -   Hardness, Knoop 682 Converted from Rockwell C hardness;    -   Hardness, Rockwell C 58;    -   Hardness, Vickers 661;    -   Izod Impact, Unnotched 63 J 46.5 ft-lb; and

Thermal Properties—

-   -   CTE, linear 20° C. 10.5 μm/m-° C. 5.83 μin/in-° F. 20-100° C.;    -   CTE, linear 250° C. 11.8 μm/m-° C. 6.56 μin/in-° F. from        0-300° C. (68-570° F.); and    -   CTE, linear 500° C. 12.5 μm/m-° C. 6.94 μin/in-° F. from        0-500° C. (68-930° F.).

In an exemplary embodiment, the AISI Type D2 Tool Steel has thefollowing material composition: Component Wt. % C 1.4-1.6 Co Max 1 Cr11-13 Mn Max 0.6 Mo 0.7-1.2 P Max 0.03 S Max 0.03 Si Max 0.6 V Max 1.1

In an exemplary embodiment, an example of a D3 material is, AISI Type D3Tool Steel that is oil-quenched from 980° C. (1800° F.) and tempered at450° C., which falls into the following subcategories: cold work steel;high carbon steel; metal; and tool steel. The AISI Type D3 Tool Steelhas the following properties:

Mechanical Properties Metric English Comments—

-   -   Hardness, Knoop 682 682 Converted from Rockwell C hardness;    -   Hardness, Rockwell C 58 58;    -   Hardness, Vickers 661 661;    -   Izod Impact, Unnotched 29 J 21.4 ft-lb; and

Thermal Properties—

-   -   CTE, linear 20° C. 10.7 μm/m-° C. 5.94 μin/in-° F. 20-100° C.;    -   CTE, linear 250° C. 12.1 μm/m-° C. 6.72 μin/in-° F. from        0-300° C. (68-570° F.); and    -   CTE, linear 500° C. 12.8 μm/m-° C. 7.11 μin/in-° F. from        0-500° C. (68-930° F.).

In an exemplary embodiment, the AISI Type D3 Tool Steel has thefollowing material composition: Component Wt. % C  2-2.35 Cr 11-13 MnMax 0.6 P Max 0.03 S Max 0.03 Si Max 0.6 V Max 1.1 W Max 1

In an exemplary embodiment, an example of a D5 material has thefollowing characteristics: Category Characteristic Principal Design Thisalloy is one of the Cold Work, high Carbon/ Features Chromium type toolsteels. It is capable of deep hardening with minimal distortion from airquenching after heat treatment. It has low resistance to heat softeningand should not be used at elevated temperatures. ApplicationsApplications include thread rolling, blanking or forming dies operatingat temperatures below 900 F. Machinability Machinability of D5 isrelatively poor. Using water hardening (W group) simple alloy tool steelas a base of 100% the D5 alloy would rate 40%. Forming Forming is bymeans of forging or machining Welding The alloy may be welded. Consultthe alloy supplier for proper procedures. Heat Treatment Preheat veryslowly up to 1500 F. then increase temperature to 1850 F. and hold attemperature for 20 to 45 minutes. Air cool (air quench). Forging Forgeat 1950 F. down to 1750 F. Do not forge below 1700 F. Cold Working Coldworking with the alloy in the annealed condition may be accomplished byconventional methods. Annealing Anneal at 1625 F. followed by slowcooling in the furnace at a rate of cooling of 40 F. per hour or less.Aging Not applicable to this alloy. Tempering Temper between 400 F.(Rockwell C 61) and 1000 F. (Rockwell C 54). Hardening See “HeatTreatment” and “Tempering”.

In an exemplary embodiment, an example of a D5 material has thefollowing material composition: Component Wt. % Carbon 1.4-1.6 Chromium11-13 Cobalt 2.5-3.5 Iron Balance Manganese  0.6 max Molybdenum 0.7-1.2Phosphorus 0.03 max Silicon  0.6 max Sulfur 0.03 max Vanadium   1 max

In an exemplary embodiment, an example of a D5 material has thefollowing physical data: Physical Characteristic Data Density (lb/in³)0.283 Specific Gravity 7.8 Melting Point (Deg F.) 2600 Modulus ofElasticity Tension 29

In an exemplary embodiment, an example of a D7 material has thefollowing characteristics: Category Characteristic Principal Design Thisalloy is one of the Cold Work, high Carbon/ Features Chromium type toolsteels. Corrosion Corrosion resistance of this alloy is better than thatof Resistance plain carbon steels. However it will rust unless givenprotective treatment. Applications include thread rolling, blanking orforming dies operating at temperatures below 900 F.

In an exemplary embodiment, an example of a D7 material has thefollowing material composition: Component Wt. % Carbon 2.15-2.5 Chromium 11.5-13.5 Iron Balance Manganese  0.6 max Molybdenum 0.7-1.2Phosphorus 0.03 max Silicon  0.6 max Sulfur 0.03 max Vanadium 3.8-4.4

In an exemplary embodiment, an example of a D7 material has thefollowing physical data: Physical Characteristic Data Density (lb/in³)0.283

In an exemplary embodiment, an example of a M2 material is, AlleghenyLudlum M2 Tool Steel, UNS T11302, which falls into the followingsubcategories: metal; tool steel. The Allegheny Ludlum M2 Tool Steel hasthe following material composition: Component Wt. % C 0.84 Cr 4.15 Fe 83Mo 4.65 V 1.85 W 5.65

In an exemplary embodiment, an example of a M4 has the followingmaterial composition: Component Wt. % Carbon 1.25-1.4  Chromium3.75-4.75 Iron Balance Manganese 0.15-0.4  Molybdenum 4.25-5.5 Phosphorus 0.03 max Silicon  0.2-0.45 Sulfur 0.03 max Tungsten 5.25-6.5 Vanadium 3.75-4.5 

In an exemplary embodiment, an example of a M4 material has thefollowing characteristics: Category Characteristic Principal Design M4is another in the Molybdenum High Speed Tool Features Steels. It has arelatively high 1.3% carbon content for high hardness and excellent wearresistance. Applications Used for cutting tools of all types formachining operations. Machinability Machinability is relatively low,rating 40% that of the water hardening (W group) tool steels which arerelatively easy to machine. Forming Forming in the annealed condition issatisfactory by conventional methods. Welding This is an alloy steel andmay be welded. Consult the supplier for details. Heat Treatment Preheatat 1450 F. and then heat rapidly to 2225 F. for 3 to 5 minutes followedby oil, salt bath or air quench. Forging Forge at 2050 F. down to 1700F. Do not attempt to continue forging below 1700 F. Cold Working Coldworking may be accomplished by conventional methods with the alloy inthe annealed condition. Annealing Anneal at 1625 F. and slow furnacecool at 40 F. per hour or less. Aging Not applicable to this alloy.Tempering Temper at 1050 F. for a Rockwell C hardness of 62 to 66.Hardening See “Heat Treatment” and “Tempering”. Corrosion Not normallyemployed in applications requiring Resistance corrosion resistance. HotWorking M4 may be hot forged. No data in regard to hot working. Consultthe alloy supplier for temperatures. Other Comments M4 is one of thebest of the Molybdenum High Speed Tool Steels in regard to wearresistance. However it has low toughness.

In an exemplary embodiment, an example of a M4 material has thefollowing physical data: Physical Characteristic Data Density (lb/in)0.295 Specific Gravity 8.16 Melting Point (Deg F.) 2600 Modulus ofElasticity Tension 29

In an exemplary embodiment, the characteristics of exemplary CPM M4, 10Vand 3V materials may be found in the resources listed below. ConeMaterials Manufacture/Distributor Data Sheet (if available) CPM M4Crucible Materials DS351 12/01 CPM M4 Corporation, Syracuse, NewCrucible Material Corp. York 10V Crucible Materials DS317 03/02 CPM 10VCorporation, Syracuse, New Crucible Material Corp. York  3V CrucibleMaterials DS406 03/02 CPM3V Corporation, Syracuse, New Crucible MaterialCorp. York

Expansion Cone Coating and Polish

Several expansion cone finish techniques may be used to reduce thesurface roughness of the an expansion cone, including for exampleapplying coating, polishing the surface, chrome plating, cryogenics andREM® Isotropic Finishing (available from Taylor Race Engineering, Plano,Tex.). When selecting a coating for an expansion cone in a system forlubricating the interface between an expansion cone and a tubular memberduring the expansion process, several factors may be considered,including the coefficient of friction between an expansion cone and atubular member, cone material hardness, cone wear resistance, surfacefinish and the compatibility of the coating to the cone material.

In several exemplary experimental embodiments, the following coatingswith specified characteristics may be utilized as a coating for anexpansion cone in a tubular member during the expansion process: PVD CVDCVD for DLC's Thermal Spray Deposition  200-450° C.  500-1000° C.200-450° C. <150° C. Temperature Hardness 2000-4000 HV 2000-5000 HV Upto 8000 HV  900-1700 HV Adhesion (Bond) Excellent Excellent ExcellentGood Coating Thickness   3-5 microns   1-5 microns  1-3 microns.003-.008 inch Coatable Most metals Many Most metals Most metalsMaterials restrictions Repairability Most coatings, Typically none,Typically none, Most coatings, strip and recoat some coatings some ableto strip and strippable burn off recoat Post Coating None Possible HeatNone Grinding or Processing Treating Machining

In an exemplary embodiment, at least two thin film deposition processesmay be used as coatings for an expansion cone in a tubular member duringthe expansion process; Chemical Vapor Deposition (CVD) and PhysicalVapor Deposition (PVD). Both processes may yield hard coatings with highlubricity for forming and cutting. Each coating is very thin, such as,for example, in the order of microns, and the bond to the expansion conesubstrate surface is a metallurgical bond. These two features of vapordeposition coatings are very conducive for high load and shearapplication. Thin film coatings are typically used with a cone materialto support the coating. Referring to FIG. 71 e, a comparison of thehardness of a few thin film coatings and cone materials is presented.

Many CVD coatings are processed at temperature above 500 C, which mayhave an impact on the expansion cone material hardness. Re-hardening isavailable for the expansion cone material in the event that hardness islost during the CVD coating process. However, for many metals, thedimensional tolerance of the component may change during there-hardening process and may need to be accounted for. In an exemplaryembodiment, a low process temperature Diamond Like Carbon (DLC) coatingmay be used as a coating for an expansion cone in a tubular memberduring the expansion process.

PVD coatings are well suited to function as a coating for an expansioncone in a tubular member during the expansion process. The PVD thin filmcoatings are typically processed at temperature below 400 C, which maynot effect the hardness of the expansion cone material. PVD typicallyproduce well bonded, high hardness coatings. In an exemplary embodiment,either a Titanium Nitride or Titanium Carbonitride coating may be usedas a coating for an expansion cone in a tubular member during theexpansion process.

The thermal spray coating process typically requires a soft expansioncone material for a high strength coating bond, which may be importantduring the tubular member expansion process due to the potential forhigh shear forces on the expansion cone. A high strength bond with anexpansion cone may be obtained with a very high velocity thermal sprayequipment. Post-coating work, such as for example, machining orgrinding, may be utilized after the application of a thermal spraycoating to an expansion cone to achieve the desired surface.

The REM® Isotropic Finishing process for an expansion cone involves twosteps. The first step, the refinement process, involves a chemicalinteraction on the surface of the expansion cone. A soft, thin (onemicron) film is formed on the surface of the expansion cone. Theexpansion cone interacts with the ceramic media in a special vibratorytub, this film is physically removed from the peaks of the processedpart and the valleys are unaffected. The chemically induced filmre-forms only at the peaks that are interacting with the vibratorymedia, and the process repeats itself. Over time, the peaks are removed,leaving only the valleys, producing the improved micro finish on theexpansion cone. The second step is the burnish process. After therequired micro finish is achieved, a mild alkaline mixture isintroduced. After a relatively short period a polished, chrome-likefinish is produced. In addition to the polishing effects, this stepeffectively removes all traces of the film formation on the expansioncone from the refinement process.

Referring to FIG. 72, an example method 7880 for radially expanding atubular member is described. In an exemplary embodiment, the expansioncone and tubular member are placed in a wellbore, step 7880. Lubricationis introduced into the interface between the expansion cone and thetubular member, step 7884. Tubular member is radially expanded by theexpansion cone using one or more conventional methods in step 7884, by,for example, displacing, translating, and/or rotating the expansion conerelative to the tubular member.

In an exemplary embodiment, one or more of the lubrication systems,expansion devices and elements of the expansion cones 5100, 5200, 5300,5400, 5500, 5600, 5700, 5800, 5900, 6000, 6100, 6200, 6300, 6600, 6700,6800, 6900, 7000 and 7100 are incorporated into the method 7880 forexpanding tubular members described above with reference to FIG. 72. Inan exemplary embodiment, one or more of the lubricant delivery systems7200, 7300, 7400, 7500, 7600, 7700, 7800 and 7900 are incorporated intothe method 7880 and apparatus for expanding tubular members describedabove with reference to FIG. 72. In an exemplary embodiment, one or moreof the lubricants described above are incorporated into the method 7880and apparatus for expanding tubular members described above withreference to FIG. 72. In an exemplary embodiment, one or more of thecone materials described above are incorporated into the method 7880 andapparatus for expanding tubular members described above with referenceto FIG. 72. In an exemplary embodiment, one or more of the cone finishtechniques described above are incorporated into the method 7880 andapparatus for expanding tubular members described above with referenceto FIG. 72.

In several exemplary embodiment, one or more of the lubrication systemsand lubricants described above are incorporated into the methods andapparatus for expanding tubular members described above with referenceto FIGS. 1-30. In several exemplary embodiments, one or more of thelubrication systems, expansion devices and elements of the expansioncones 5100, 5200, 5300, 5400, 5500, 5600, 5700, 5800, 5900, 6000, 6100,6200, 6300, 6600, 6700, 6800, 6900, 7000 and 7100 are incorporated intothe methods and apparatus for expanding tubular members described abovewith reference to FIGS. 1-99. In several exemplary embodiments, one ormore of the lubricant delivery systems 7200, 7300, 7400, 7500, 7600,7700, 7800 and 7900 are incorporated into the methods and apparatus forexpanding tubular members described above with reference to FIGS. 1-99.In several exemplary embodiments, one or more of the lubricantsdescribed above are incorporated into the methods and apparatus forexpanding tubular members described above with reference to FIGS. 1-99.In an exemplary embodiment, one or more of the cone materials describedabove are incorporated into the methods and apparatus for expandingtubular members described above with reference to FIGS. 1-99. In anexemplary embodiment, one or more of the cone finish techniquesdescribed above are incorporated into the methods and apparatus forexpanding tubular members described above with reference to FIGS. 1-99.

In this manner, the amount of force required to radially expand atubular member in the formation and/or repair of a wellbore casing,pipeline, or structural support is significantly reduced. Furthermore,the increased lubrication provided to the interface between an expansioncone and tubular member greatly reduces the amount of galling or seizurecaused by the interface between the expansion cone and the tubularmember during the radial expansion process thereby permitting largercontinuous sections of tubulars to be radially expanded in a singlecontinuous operation. Thus, use of the expansion cones 5100, 5200, 5300,5400, 5500, 5600, 5700, 5800, 5900, 6000, 6100, 6200, 6300, 6600, 6700,6800, 6900, 7000 and 7100 and/or lubricant delivery systems 7200, 7300,7400, 7500, 7600, 7700, 7800 and 7900 and/or the lubricants describedabove reduces the operating pressures required for radial expansion andthereby reduces the sizes of the required hydraulic pumps and relatedequipment. In addition, failure, bursting, and/or buckling of tubularmembers during the radial expansion process is significantly reduced,and the success ratio of the radial expansion process is greatlyincreased.

In several exemplary embodiments, one or more of the lubricationsystems, lubricants, lubricant delivery systems, expansion conematerials and cone finish techniques described above may be incorporatedinto one or more of the following conventional expansion devices: a) anexpansion cone; b) a rotary expansion device; c) a hydroformingexpansion device; d) an impulsive force expansion device; e) any one ofthe expansion devices commercially available from, or disclosed in anyof the published patent applications or issued patents, of WeatherfordInternational, Baker Hughes, Halliburton Energy Services, Shell Oil Co.,Schlumberger, and/or Enventure Global Technology L.L.C.

In several exemplary embodiments, a tubular members may be radiallyexpanded and plastically deformed using one or more of the lubricationsystems, lubricants, lubricant delivery systems, expansion conematerials and cone finish techniques described above in conjunction withother conventional methods for radially expanding and plasticallydeforming tubular members such as, for example, internal pressurization,hydroforming, and/or roller expansion devices and/or any one orcombination of the conventional commercially available expansionproducts and services available from Baker Hughes, WeatherfordInternational, and/or Enventure Global Technology L.L.C.

In several exemplary experimental embodiments, many of the lubricantsspecified above were tested with different types of expansion cones intubular member in different conditions to determine the expansion forcesnecessary to expand the respective tubular members. For comparisonpurposes, tests were also performed on various different tubular membersand cones without lubricants. The results of the tests relate to theeffect of friction on a system for lubricating the interface between anexpansion cone and a tubular member.

The following equation defines the effective force (F_(eff)) of a systemfor reducing the coefficient of friction in the interface between anexpansion cone and a tubular member during the expansion process:F _(eff=) k _(geo)(F/(2 sin β+μ_(fric));  (25)where:

F=Force on Tool (Input Pressure)

F_(eff)=Effective Force on the Cone Surface

k_(geo)=Coefficient of Geometry

μ_(fric)=Coefficient of Friction

β=Cone Angle.

The following equation defines the expansion force (F) on an expansioncone of a system radially expanding a tubular member using an expansioncone during the expansion process:F=πDt(1+f cot β)Yε  (26)where:

F—Expansion force;

D—Inside diameter of tubular member;

t—Wall thickness of tubular member'

f—Coefficient of friction between the tubular member and expansion cone;

Y—Yield strength the tubular material; and

ε—Expansion rate of the tubular material.

FIG. 73 a illustrates the forces on expansion cone 8000 in tubularmember 8002 during the expansion process. It is apparent from theequations listed directly above that the load on the expansion conesurface may be an important parameter in system and that the exemplaryembodiments of structures of the surfaces of the systems; mechanisms fordelivering lubricating fluid to the surfaces of the systems; lubricatingfluids delivered to the system; different compositions of the system;and compositions of the tubular member described above have an impact onthat load.

FIG. 73 b illustrates example elements in a system for lubricating theinterface between an expansion cone and a tubular member during theexpansion process that may have an impact on the effective frictionforces of the system. Such elements include, the surface 8102 of thetubular member 8100, the coating 8104 on the surface 8102 such as, forexample, a low friction soft coating, the surface 8106 of the expansioncone 8108, the coating 8110 on the expansion cone 8108 such as, forexample, a self-lubricating hard film, and the lubricant 8112 such as,for example, oil or grease and lubricated mud located between thetubular member 8100 and the expansion cone 8108. Regarding the surfacesof expansion cone 8108 and tubular member 8100, both the surfaceroughness, such as, for example, a rough or polished finish, and thetexture, such as, for example, a pattern in the surface may play a rolein contributing to the overall friction of the system.

Referring to FIGS. 73 c and 73 d, illustrations of a smoother expansioncone finish and a rougher expansion cone finish, respectively, will nowbe described. For discussion purposes only, the term roughness refers tothe roughness 8010 of the planar part of the surface. The term texturerefers to the patter in the surface, such as, for example, the holes8012 in the surface. The holes may represent oil pockets will captureoil that in turn acts as a liquid ball bearing and thus may increase thelubricity of the surface of the expansion cone. A range of roughness foran expansion cone that may decrease the coefficient of friction betweenan expansion cone and a tubular member during radial expansion andplastic deformation is 0.02-0.1 micrometers.

In an exemplary embodiment, a calculation was completed to determine theeffective force F_(eff) on a cone surface and the energy equationsnecessary to calculate frictional effects for tribological elements,that is the elements that have an impact on coefficient of frictionbetween an expansion cone and a tubular member during the expansionprocess. The system was modeled for static and dynamic conditions. Thetool velocity in the system allowed for static kinematic calculationswith static and dynamic coefficients of friction. A preliminaryevaluation shows that up to 25% of input pressure may be required tocompensate for dynamic frictional effects and that the effective forceon the cone could exceed 5000 psi during tubular member expansion.

During the expansion process, a tubular member may withstand a finiteamount of expansion pressure from an expansion cone, the maximumacceptable expansion pressure, beyond which tubular member failure mayoccur, including fracturing and splitting. Laboratory tests have shownthat the maximum acceptable expansion pressure for an 5½″ LSX-80 tubularmember having a 0.3″ wall thickness is approximately 5000 psi. Referringto FIG. 74, a chart illustrates a curve depicting the pressure (y-axis)versus coefficient of friction (x-axis) for an 5½″ LSX-80 tubular memberhaving a 0.3″ wall thickness. The maximum coefficient of frictioncorresponding to the maximum acceptable pressure for the 5½″ LSX-80tubular member having a 0.3″ wall thickness is approximately 0.2.Referring to FIGS. 75 and 76, charts illustrate information similar tothat shown in FIG. 74 on a logarithmic scale; one showing pressure interms of pounds per square inch and the other showing pressure in termsof pounds. As illustrated in FIGS. 74, 75 and 76, as the coefficient offriction increases, the expansion pressure increases.

Referring to FIG. 77, a chart depicting the results in an exemplaryexperimental embodiment that shows the expansion forces in pounds persquare inch over time applied to a 6″ LSX80 tubular member coated with aGear Kote coating, which is a graphite based coating distributed byCommercial Coating Services International, Ltd. The expansion processbegan with no lubricant between the expansion cone and the tubularmember, period 8900. A steady increase in expansion force was observed.After the introduction of oil between the expansion cone and the tubularmember at point 8902, the expansion force decreased significantly overthe period 8904 suggesting that expansion force is related to thecoefficient of friction between the expansion cone and the tubularmember. Expansion forces increased over time during the expansionprocess in the period 8904 after the introduction of oil, but did so ata much slower rate than under the dry friction conditions in period8900. Once a lubricant, such as, for example oil, is introduce duringthe expansion process, the system coefficient of friction is reduced andthus the expansion forces decreases.

In several exemplary embodiments, many of the lubricants specified abovewere tested with different types of expansion cones in tubular membersin different conditions to determine the expansion forces necessary toexpand the respective tubular members. For comparison purposes, testswere also performed on various different tubular members and cones without lubricants. The results of the test are shown in FIG. 78-FIG. 98.

Referring to FIG. 78, a chart depicting the results of experimental testthat show the coefficient of friction for several different combinationsof expansion systems using a 1⅝″ Low Carbon Steel expansion cone made ofD2 material is shown. The following samples are represented on thechart: Expansion System Components Expansion Tubular Cone MemberExternal Expansion Tubular Internal Surface Cone Coefficient Samplemember Coating Coating Lubricant Finish of Friction 1 Heavy None NoneNone None 0.36-0.40 corroded 2 Clean None None None None 0.16-0.22tubular member 3 Clean None None Oleon None 0.14-0.16 tubular member 4Clean Graphite None None None 0.12-0.15 tubular based member coating 5Clean None None H1 None 0.09-0.14 tubular member 6 Clean EGT MS- NoneNone None 0.08-0.10 tubular 9075 member 7 Clean EGT MS- None H1 None0.04-0.05 tubular 9075 member 8 Clean EGT MS- DC53 cone H1 REM 0.02-0.03tubular 9075 material + Phygen member filmThe lowest coefficient of friction, approximately 0.02, resulted fromSample 8. Sample 7 also produce a low coefficient of friction in theorder of approximately 0.05EGT MS-9075 is a Teflon based coating (polytetrafluoroethylene or PTFE),distributed by Enventure Global Technology, L.L.C., Houston Tex., isshown. Phygen film is a chrome nitride coating and is distributed byPhygen, Inc., Minneapolis, Minn.

Referring to FIG. 79 a, a three dimensional photograph having a 5×magnification and a field of the view 1.20×0.90 mm of the surface of anexpansion cone made of D2 material is shown. The expansion cone made ofD2 material, has the following surface characteristics: SurfaceCharacteristic Value Ra: 277.930 nm Rz: 3.13 um Rpk: 377.167 nm Rk:829.31 nm Rvk: 216.287 nm Sty X Pc: 3.88/mm Sty Y Pc: 6.13/mmNormVolume: 0.822 BCM

The surface characteristics listed in the table above are well known.Some of the characteristics listed in the table above have the followingmeanings:

-   -   a. Ra is the roughness average, is the arithmetic average of the        absolute values of the surface height deviations measured from        the best fitting plane, cylinder or sphere;    -   b. Rz is the average maximum height of the surface;    -   c. Rpk—is the reduced peak height, a measure of the peak height        above the nominal/core roughness;    -   d. Rvk is the reduced valley depth, which is a measure of the        valley depth below the nominal/core roughness; and    -   e. Rk is the core roughness depth which is a measure of the        nominal or “core” roughness (peak-to-valley) of the surface with        the predominant peaks and valleys removed.

Referring to FIG. 79 b, a three dimensional photograph having a 5×magnification and a field of the view 1.20×0.90 mm of the surface of anexpansion cone made of DC53 material having a Phygen film and REM polishis shown. The expansion cone made of DC53 material, has the followingsurface characteristics: Surface Characteristic Value Ra: 60.205 nm Rz:1.99 um Rpk: 25.009 nm Rk: 152.12 nm Rvk: 92.963 nm Sty X Pc: 2.21/mmSty Y Pc: 3.53/mm NormVolume: 0.047 BCM

Referring to FIGS. 80 a and 80 b, photo micrographs of the expansioncone made of D2 material shown in FIG. 79 a and the expansion cone madeof DC53 material shown in FIG. 79 b are shown, respectively.

Referring to FIGS. 81 a and 81 b, an x-profile of the an expansion conemade of D2 material shown in FIG. 79 a and the expansion cone made ofDC53 shown in FIG. 81 b are shown, respectively. Note in FIG. 81 b thata hole pocket 9000 in surface the expansion cone made of DC53 exists,which may create an oil pocket. Hole pockets may be desirable and mayenhance the reduction of the effect of friction on the expansion system.Hole pockets may collect oil, act as a liquid ball bearings when incontact with a tubular member and may increase the lubricity of thesystem by introducing more lubricant in the interface between theexpansion cone and the tubular member.

Referring to FIGS. 82 a and 82 b, the bearing ratio for the expansioncone made of D2 shown in FIG. 79 a and the expansion cone made of DC53shown in FIG. 79 b are shown, respectively. The bearing ratio representsthe length of material surface (expressed as a percentage of theevaluation length L) at a depth below the highest peak.

Referring to FIG. 83 a, a three dimensional photograph having a 50×magnification and a field of the view 1.20×0.90 mm of the surface of anexpansion cone made of D2 material is shown. The expansion cone made ofD2 material, has the following surface characteristics: SurfaceCharacteristic Value Ra: 275.671 nm Rz: 2.34 um Rpk: 262.729 nm Rk:872.91 nm Rvk: 270.620 nm Sty X Pc: 22.83/mm Sty Y Pc: 38.65/mmNormVolume: 0.469 BCM

Referring to FIG. 83 b, three dimensional photographs having a 50×magnification and a field of the view 1.20×0.90 mm of the surface of anexpansion cone made of DC53 material having a Phygen film and REM polishis shown. The expansion cone made of DC53 material, has the followingsurface characteristics: Surface Characteristic Value Ra: 55.085 nm Rz:678.35 nm Rpk: 32.764 nm Rk: 163.53 nm Rvk: 82.624 nm Sty X Pc: 48.84/mmSty Y Pc: 61.73/mm NormVolume: 0.075 BCM

Referring to FIGS. 84 a and 84 b, photo micrographs of the expansioncone made of D2 material shown in FIG. 83 a and the expansion cone madeof DC53 material shown in FIG. 83 b are shown, respectively.

Referring to FIGS. 85 a and 85 b, an x-profile of the expansion conemade of D2 material shown in FIG. 83 a and the expansion cone made ofDC53 material shown in FIG. 83 b are shown, respectively.

Referring to FIGS. 86 a and 86 b, the bearing ratio for the expansioncone made of D2 material shown in FIG. 83 a and the expansion cone madeof DC53 material shown in FIG. 83 b, respectively, are shown.

Referring to FIG. 87, a chart depicting the results of experimentaltests that show the expansion forces in terms of load for severaldifferent combinations of expansion systems, which range from a systemusing only a cone to a system with a cone, combined with one or more ofthe friction reduction mechanisms, such as for example, a tubular membercoating, a cone coating, a lubricant between the expansion cone and thetubular member, and a cone finish, in a corroded tubular member exposedto seawater for 24 hours is shown. Several of the tribological elementsidentified in FIG. 39 a analyzed during the tests. The following samplesare represented on the chart: Expansion System Components ExpansionTubular Cone Member External Expansion Approximate Internal Surface ConeLoad Range Sample Cone Material Coating Coating Lubricant Finish (Lbs) 1DC53 None Phygen film None REM 22000-23500 2 D2 None None None None22300-22900 3 DC53 None Phygen film H1 REM 17000-17200 4 D2 None None H1None 20500-20900 5 DC53 None Phygen film H6 REM 15800-16000 6 D2 NoneNone H6 None 16900-17100 7 D2 Gear None None None 15800-17500 Kote 8 D2Gear None Sea None 13800-15500 Kote Water

Referring to FIG. 88, a chart depicting the results of experimentaltests that show the expansion forces in terms of load for severaldifferent combinations of expansion systems in a tubular member coatedwith EGT MS-9075, distributed by Enventure Global Technology, L.L.C.,Houston Tex., is shown. The following samples are represented on thechart: Expansion System Components Expansion Tubular Cone MemberExternal Expansion Approximate Internal Surface Cone Load Range SampleExpansion Cone Coating Coating Lubricant Finish (Lbs) 1 DC53 EGT MS-Phygen film None REM 22000-23500 9075 2 D2 EGT MS- None None None22300-22900 9075 3 DC53 EGT MS- Phygen film H1 REM 12900-13200 9075 4 D2EGT MS- None H1 None 12000-12300 9075 5 DC53 EGT MS- Phygen film H6 REM12800-12900 9075 6 D2 EGT MS- None H6 None 13500-13800 9075 7 D2 GearNone None None 15800-17500 Kote 8 D2 Gear None Sea None 13800-15500 KoteWater

Referring to FIG. 89, a chart depicting the results of experimentaltests that show the expansion forces in terms of load for severaldifferent combinations of expansion systems in a tubular member coatedwith a Brighton White Teflon-based coating with sea water is shown. Thefollowing samples are represented on the chart: Expansion SystemComponents Expansion Tubular Cone Member External Internal SurfaceExpansion Approximate Sample Cone Coating Coating Lubricant Cone FinishLoad Range (Lbs) 1 DC53 Brighton Phygen film None REM 22000-23500 WhiteTeflon- based 2 D2 Brighton None None None 22300-22900 White Teflon-based 3 DC53 Brighton Phygen film H1 REM 11500-12000 White Teflon- based4 D2 Brighton None H1 None 13200-14000 White Teflon- based 5 DC53Brighton Phygen film H6 REM 12800-13100 White Teflon- based 6 D2Brighton None H6 None 12200-12500 White Teflon- based 7 D2 Gear KoteNone None None 15800-17500 8 D2 Gear Kote None Sea None 13800-15500Water

Referring to FIG. 90, a chart depicting the results of experimentaltests that show the expansion forces in terms of load for severaldifferent combinations of expansion systems in a tubular member coatedwith Brighton Grey Acrilic-based coating is shown. The following samplesare represented on the chart: Expansion System Components ExpansionTubular Cone Member External Internal Surface Expansion ApproximateSample Cone Coating Coating Lubricant Cone Finish Load Range (Lbs) 1DC53 Brighton Phygen film None REM 22000-23500 Grey Acrilic- based 2 D2Brighton None None None 22300-22900 White Teflon 3 DC53 Brighton Phygenfilm H1 REM 13000-13200 Grey Acrilic- based 4 D2 Brighton None H1 None14000-14400 Grey Acrilic- based 5 DC53 Brighton Phygen film H6 REM12700-12900 Grey Acrilic- based 6 D2 Brighton None H6 None 14300-14800Grey Acrilic- based 7 D2 Gear Kote None None None 15800-17500 8 D2 GearKote None Sea None 13800-15500 Water

Referring to FIG. 91, a chart depicting the results of experimentaltests that show the expansion forces in terms of load for severaldifferent combinations of expansion systems in a tubular member isshown. The following samples are represented on the chart: ExpansionSystem Components Tubular Expansion Cone Member External ExpansionInternal Surface Cone Approximate Sample Cone Coating Coating LubricantFinish Load Range(Lbs) 1 DC53 Phygen film None REM 17800-18200 2 DC53Phygen film H1 REM 14400-14900 3 DC53 Phygen film H7 REM 16400-17200

Referring to FIG. 92, a chart depicting the results of experimentaltests that show the expansion forces in terms of load for severaldifferent combinations of expansion systems in a tubular member isshown. The following samples are represented on the chart: ExpansionSystem Components Tubular Expansion Cone Member External ApproximateInternal Surface Expansion Load Range Sample Cone Coating CoatingLubricant Cone Finish (Lbs) 1 DC53 None Phygen film None REM 15000-177002 DC53 None Phygen film Oleon REM 16400-17400 3 DC53 None Phygen film H1REM 16300-16800 4 DC53 None Phygen film H2 REM 15800-16800 5 DC53 NonePhygen film H3 REM 14500-16800 6 DC53 None Phygen film H4 REM15300-17200 7 DC53 None Phygen film H5 REM 14100-16900 8 DC53 NonePhygen film H6 REM 14600-15800

Referring to FIG. 93, a chart depicting the results of experimentaltests that show the expansion forces in terms of load for severaldifferent combinations of expansion systems in a tubular member isshown. The following samples are represented on the chart: ExpansionSystem Components Tubular Expansion Cone Member External ExpansionInternal Surface Cone Approximate Sample Cone Coating Coating LubricantFinish Load Range (Lbs) 1 None None None None None 0 2 D2 Gear Kote NoneNone None 15500-17600 3 DC53 None Phygen film Oleon REM 16800-17100 4DC53 None Phygen film H1 REM 16300-16800 5 DC53 None Phygen film H2 REM15700-16200 6 DC53 None Phygen film H3 REM 14500-15400 7 DC53 NonePhygen film H4 REM 17700-18100 8 DC53 None Phygen film H5 REM14100-14500 9 DC53 None Phygen film H6 REM 14600-14800 10 16400-16600 11DC53 None Phygen film Belesta REM 14800-15200

Referring to FIG. 94, a chart depicting the results of experimentaltests that shows the expansion forces in terms of load for severaldifferent combinations of expansion systems in a tubular member isshown. The following samples are represented on the chart: ExpansionSystem Components Expansion Tubular Cone Member External ExpansionApproximate Sam- Internal Surface Lubri- Cone Load Range ple ConeCoating Coating cant Finish (Lbs) 1 D2 Gear Kote None None REM15500-17700 2 D2 Gear Kote None Oleon REM 16400-17400 3 D2 Gear KoteNone H1 REM 16300-16800 4 D2 Gear Kote None H2 REM 15800-16800 5 D2 GearKote None H4 REM 14500-16800 6 D2 Gear Kote None H5 REM 15300-17200 7 D2Gear Kote None H6 REM 14100-16900 8 D2 Gear Kote None H7 REM 14600-15400

Referring to FIG. 95, a chart depicting the results of experimentaltests that show the expansion forces in terms of load for severaldifferent combinations of expansion systems in a tubular member isshown. The following samples are represented on the chart: ExpansionSystem Components Expansion Tubular Cone Member External ExpansionApproximate Sam- Internal Surface Lubri- Cone Load Range ple ConeCoating Coating cant Finish (Lbs) 1 DC53 None Phygen film None REM19200-23000 2 DC53 None Phygen film None REM 13800-15500 3 DC53 NonePhygen film Oleon REM 17800-18400 4 DC53 None Phygen film H1 REM14300-14500 5 DC53 None Phygen film H3 REM 15000-15500 6 DC53 NonePhygen film H5 REM 15800-16100 7 DC53 None Phygen film H6 REM15600-15900

Referring to FIG. 96, a chart depicting the results of experimentaltests that show the expansion forces in terms of load for severaldifferent combinations of expansion systems in a LSX80 tubular member isshown. The following samples are represented on the chart: ExpansionSystem Components Expansion Tubular Cone Member External ExpansionApproximate Sam- Internal Surface Cone Load Range ple Cone CoatingCoating Lubricant Finish (Lbs) 1 D2 None None Oleon None 19700-20100 2D2 None None H1 None  1600-16300 3 D2 None None H2 None 16800-17400 4 D2None None H3 None 17200-17900 5 D2 None None H4 None 15500-15700 6 D2None None H5 None 17700-18000 7 D2 None None H6 None 14700-15200 8 D2None None H7 None 15800-16000 9 D2 None None HPL None 18500-18800

Referring to FIG. 97, a chart depicting the results of experimentaltests that show the expansion forces in terms of load for severaldifferent combinations of expansion systems in a LSX80 tubular member isshown. The following samples are represented on the chart: ExpansionSystem Components Expansion Tubular Cone Member External ExpansionApproximate Sam- Internal Surface Lubri- Cone Load Range ple ConeCoating Coating cant Finish (Lbs) 1 D2 Gear Kote None None None16000-16200 2 D2 Gear Kote None Oleon None  1500-15600 3 D2 Gear KoteNone H1 None 12500-12700 4 D2 Gear Kote None H2 None 14500-14700 5 D2Gear Kote None H3 None 13900-14100 6 D2 Gear Kote None H4 None12500-12800 7 D2 Gear Kote None H5 None 14100-14500 8 D2 Gear Kote NoneH6 None 11600-12200 9 D2 Gear Kote None H7 None 12400-12700

Referring to FIG. 98, a chart depicting the results of experimentaltests that the expansion forces in terms of load for several differentcombinations of expansion systems in a LSX80 tubular member is shown.The following samples are represented on the chart: Expansion SystemComponents Expansion Tubular Cone Approximate Member External ExpansionLoad Sam- Internal Surface Lubri- Cone Range ple Cone Coating Coatingcant Finish (Lbs) 1 D2 Gear Kote None None None 13400-13700 2 D2 GearKote None Oleon None 12700-13000 3 D2 Gear Kote None H1 None 11700-121004 D2 Gear Kote None H3 None 12700-12900 5 D2 Gear Kote None H5 None11500-12200

Referring to FIG. 99 a, another exemplary embodiment of a system forlubricating the interface between an expansion cone and a tubular memberduring the expansion process will now be described. As illustrated inFIG. 99 a, an expansion cone 10000, having a front end 10000 a and arear end 10000 b, includes a tapered portion 10005 having an outersurface 10010, a spiral circumferential grooves 10015, and radial ports10016. Referring to FIG. 99 b, a photo micrograph of the outer surface10010 of expansion cone 10000 of FIG. 99 a is shown.

Referring to FIG. 99 c, an embodiment of a system 10100 for lubricatingthe interface between an expansion cone and a tubular member during theexpansion process will now be described. As illustrated in FIG. 99 c, anexpansion cone 10102 includes a body 10104 that defines a centrallypositioned longitudinal passage 10106, longitudinal passage 10112,radial passage 10116 a, fluidicly coupled to the longitudinal passage10112, radial passages, fluidicly coupled to the longitudinal passage10106, and includes a front end face 10120, a rear end face 10122, and atapered external expansion surface 10124 including spaced apart externalgrooves, 10124 a, 10124 b, and 10124 c, that are fluidicly coupled tothe radial passages, fluidicly coupled to the longitudinal passage 10106through radial ports, respectively. A tubular member 10128 that definesa longitudinal passage 10128 a and is received within, mates with, andis coupled to the centrally positioned longitudinal passage 10106 of theexpansion cone. A tubular member 10128 that defines a longitudinalpassage 10128 a and is received within, mates with, and is coupled tothe centrally positioned longitudinal passage 10112 of the expansioncone.

In an exemplary embodiment, during operation of the system 10100, theexpansion cone 10102 is positioned within, and displaced relative to, anexpandable tubular member thereby radially expanding and plasticallydeforming the expandable tubular member. In an exemplary embodiment, theexpansion cone 10102 is displaced relative to the expandable tubularmember by injecting a pressurized fluidic material 10132 into andthrough the passage 10128 a of the tubular member 10128. As a result,the expansion cone 10102 is displaced in a direction 10133 relative tothe expandable tubular member. In an exemplary embodiment, the fluidicmaterial 10132 includes one or more lubricant materials suitable forlubricating the interface between the expansion cone 10102 and theexpandable tubular member during the radial expansion process. In anexemplary embodiment, a second pressurized fluidic material 10144 isinjected into and through the passage 10129 a of the tubular member10129 though pump 10130. In an exemplary embodiment, the fluidicmaterial 10144 includes one or more lubricant materials suitable forlubricating the interface between the expansion cone 10102 and theexpandable tubular member during the radial expansion process. Thepressurized fluidic material 10132 may be then conveyed into theexternal grooves, 10124 a, 10124 b, and 10124 c, into an interfacebetween the expansion cone 10102 and the expandable tubular member.Similarly, in an exemplary embodiment, the fluidic material 10132 isconveyed through the radial passage 10129 a, of the tubular member 10129and through radial passage, 10116, into a passageway between theexpansion cone 10102 and the tubular member.

In an exemplary embodiment, the rate of injection of the fluidicmaterial 10144 into the external grooves, 10124 a, 10124 b, and 10124 c,depends on the selected operating pressure of the fluidic material. Inthis manner, during the radial expansion process, the fluidic material10144 may be controllably injected and metered into the interfacebetween the tapered external expansion surface 10124 of the expansioncone 10102 and the expandable tubular member 10130 continuously duringthe radial expansion and plastic deformation of the tubular member. Inan exemplary embodiment, the fluidic material 10144 may be injected intothe external grooves, 10124 a, 10124 b, and 10124 c only when required,or as desired. Thus, the trailing edge portion of the interface betweenthe tapered external expansion surface 10124 of the expansion cone 10102and the expandable tubular member 10130 may be provided with anincreased supply of lubricant, thereby reducing the amount of forcerequired to radially expand and plastically deform the expandabletubular member.

The rate of injection of fluidic material 10132 into passageway 10152between expansion cone 10100 and tubular member also depends theselected operating pressure of the fluidic material. Since, both thepressures for both fluidic materials, 10132 and 10144, are individuallycontrolled, the pressures may be set at different operating pressures.In this manner, different areas of the interface between the expansioncone 10100 and a tubular member, during the radial expansion and plasticdeformation of the tubular member using the expansion cone, can beprovided with different formulations of lubricant materials anddifferent operating pressures thereby permitting the control of frictionwithin the interface to be precisely controlled.

One of the problems of the pipe material selection for expandabletubular application is an apparent contradiction or inconsistencybetween strength and elongation. To increase burst and collapsestrength, material with higher yield strength is used. The higher yieldstrength generally corresponds to a decrease in the fracture toughnessand correspondingly limits the extent of achievable expansion.

It is desirable to select the steel material for the tubing by balancingsteel strength with amount absorbed energy measure by Charpy testing.Generally these tests are done on samples cut from tubular members. Ithas been found to be beneficial to cut directional samples bothlongitudinally oriented (aligned with the axis) and circumferentiallyoriented (generally perpendicular to the axis). This method of selectingsamples is beneficial when both directional orientations are used yetdoes not completely evaluate possible and characteristic anisotropythroughout a tubular member. Moreover, for small diameter tubing samplesrepresentative of the circumferential direction may be difficult andsometimes impossible to obtain because of the significant curvature ofthe tubing.

To further facilitate evaluation of a tubular member for suitability forexpansion it has been found beneficial according to one aspect of theinvention to consider the plastic strain ratio. One such ratio is calleda Lankford value (or r-value) which is the ratio of the strainsoccurring in the width and thickness directions measured in a singletension test. The plastic strain ratio (r or Lankford-value) with avalue of greater than 1.0 is found to be more resistant to thinning andbetter suited to tubular expansion. Such a Lankford value is found to bea measure of plastic anisotropy. The Lankford value (r) may becalculated by the Equation 2 below: $\begin{matrix}{r = \frac{\ln\quad\frac{b_{o}}{b_{k}}}{\ln\quad\frac{L_{k}b_{k}}{l_{o}b_{o}}}} & {{Equation}\quad 2}\end{matrix}$where,r—normal anisotropy coefficientb_(o) & b_(k)—initial and final widthL_(o) & L_(k)—initial and final length

However, it is time consuming and labor intensive for this parameter tobe measured using samples cut from real parts such as from the tubularmembers. The tubular members will have anisotropic characteristics dueto crystallographic or “grain” orientation and mechanically induceddifferences such as impurities, inclusions, and voids, requiringmultiple samples for reliably complete information. Moreover, withindividual samples, only local characteristics are determined and thecomplete anisotropy of the tubular member may not be determinable.Further some of the tubular members have small diameters so that cuttingsamples oriented in a circumferential direction is not always possible.Information regarding the characteristics in the circumferentialdirection has been found to be important because the plastic deformationduring expansion of the tubular members occurs to a very large extent inthe circumferential direction,

One aspect of the present exemplary embodiments comprises thedevelopment of an improved solution for anisotropy evaluation, includinga kind of plastic strain ratio similar to the Lankford parameter that ismeasured using real tubular members subjected to axial loading.

FIG. 100 depicts in a schematic fragmentary cross-sectional view along aplane along and through the axis 1002 of a tubular member 1000 that istested with axial opposed forces 1004 and 1005. The tubular member 1000is axially stretched beyond the elastic limit, through yielding and toultimate yield or fracture. Measurements of the force and the OD and IDduring the process produce test data that can be used in the formulabelow to produce an expandability coefficient “f” as set forth inEquation 1 above. Alternatively a coefficient called a formabilityanisotropy coefficient F(r) that is function of the normal anisotropyLankford coefficient r may be determined as in Equation 3 below:$\begin{matrix}{{F(r)} = \frac{\ln\quad\frac{b_{o}}{b_{k}}}{\ln\quad\frac{L_{k}b_{k}}{l_{o}b_{o}}}} & {{Equation}\quad 3}\end{matrix}$F(r)—formability anisotropy coefficientb_(o) & b_(k)—initial and final tube area (inch²)L_(o) & L_(k)—initial and final tube length (inch)b=(D²−d²)/4—cross section tube area.

In either circumstance, f or F(r), the use of this testing method for anentire tubular member provides useful information including anisotropiccharacteristics or anisotropy of the tubular member for selecting orproducing beneficial tubular members for down hole expansion, similar tothe use of the Lankford value for a sheet material.

Just as values for stress and strain may be plotted for solid specimensamples, as schematically depicted in FIG. 101, the values forconducting a test on the tubular member may also be plotted, as depictedin FIG. 102. On this basis the expansion coefficient f (or theformability coefficient F(r)) may be determined. It will be the best tomeasure distribution (Tensile-elongation) in longitudinal andcircumferential directions simultaneously.

The foregoing expandability coefficient (or formability coefficient) isfound to be useful in predicting good expansion results and may befurther useful when used in combination with one or more otherproperties of a tubular member selected from stress-strain properties inone or more directional orientations of the material, strength &elongation, Charpy V-notch impact value in one or more directionalorientations of the material, stress burst rupture, stress collapserupture, yield strength, ductility, toughness, and strain-hardeningexponent (n-value), and hardness.

In an exemplary embodiment, a tribological system is used to reducefriction and thereby minimize the expansion forces required during theradial expansion and plastic deformation of the tubular members thatincludes one or more of the following: (1) a tubular tribology system;(2) a drilling mud tribology system; (3) a lubrication tribology system;and (4) an expansion device tribology system.

In an exemplary embodiment, the tubular tribology system includes theapplication of coatings of lubricant to the interior surface of thetubular members.

In an exemplary embodiment, the drilling mud tribology system includesthe addition of lubricating additives to the drilling mud.

In an exemplary embodiment, the lubrication tribology system includesthe use of lubricating greases, self-lubricating expansion devices,automated injection/delivery of lubricating greases into the interfacebetween an expansion device and the tubular members, surfaces within theinterface between the expansion device and the expandable tubular memberthat are self-lubricating, surfaces within the interface between theexpansion device and the expandable tubular member that are textured,self-lubricating surfaces within the interface between the expansiondevice and the expandable tubular member that include diamond and/orceramic inserts, thermosprayed coatings, fluoropolymer coatings, PVDfilms, and/or CVD films.

In an exemplary embodiment, the tubular members include one or more ofthe following characteristics: high burst and collapse, the ability tobe radially expanded more than about 40%, high fracture toughness,defect tolerance, strain recovery @ 150 F, good bending fatigue, optimalresidual stresses, and corrosion resistance to H₂S in order to provideoptimal characteristics during and after radial expansion and plasticdeformation.

In an exemplary embodiment, the tubular members are fabricated from asteel alloy having a charpy energy of at least about 90 ft-lbs in orderto provided enhanced characteristics during and after radial expansionand plastic deformation of the expandable tubular member.

In an exemplary embodiment, the tubular members are fabricated from asteel alloy having a weight percentage of carbon of less than about0.08% in order to provide enhanced characteristics during and afterradial expansion and plastic deformation of the tubular members. In anexemplary embodiment, the tubular members are fabricated from a steelalloy having reduced sulfur content in order to minimize hydrogeninduced cracking.

In an exemplary embodiment, the tubular members are fabricated from asteel alloy having a weight percentage of carbon of less than about0.20% and a charpy-V-notch impact toughness of at least about 6 joulesin order to provide enhanced characteristics during and after radialexpansion and plastic deformation of the tubular members.

In an exemplary embodiment, the tubular members are fabricated from asteel alloy having a low weight percentage of carbon in order to enhancetoughness, ductility, weldability, shelf energy, and hydrogen inducedcracking resistance.

In several exemplary embodiments, the tubular members are fabricatedfrom a steel alloy having the following percentage compositions in orderto provide enhanced characteristics during and after radial expansionand plastic deformation of the tubular members: C Si Mn P S Al N Cu CrNi Nb Ti Co Mo EXAMPLE A 0.030 0.22 1.74 0.005 0.0005 0.028 0.0037 0.300.26 0.15 0.095 0.014 0.0034 EXAMPLE 0.020 0.23 1.70 0.004 0.0005 0.0260.0030 0.27 0.26 0.16 0.096 0.012 0.0021 B MIN EXAMPLE B 0.032 0.26 1.920.009 0.0010 0.035 0.0047 0.32 0.29 0.18 0.120 0.016 0.0050 MAX EXAMPLEC 0.028 0.24 1.77 0.007 0.0008 0.030 0.0035 0.29 0.27 0.17 0.101 0.0140.0028 0.0020 EXAMPLE D 0.08 0.30 0.5 0.07 0.005 0.010 0.10 0.50 0.10EXAMPLE E 0.0028 0.009 0.17 0.011 0.006 0.027 0.0029 0.029 0.014 0.0350.007 EXAMPLE F 0.03 0.1 0.1 0.015 0.005 18.0 0.6 9 5 EXAMPLE G 0.0020.01 0.15 0.07 0.005 0.04 0.0025 0.015 0.010

In an exemplary embodiment, the ratio of the outside diameter D of thetubular members to the wall thickness t of the tubular members rangefrom about 12 to 22 in order to enhance the collapse strength of theradially expanded and plastically deformed tubular members.

In an exemplary embodiment, the outer portion of the wall thickness ofthe radially expanded and plastically deformed tubular members includestensile residual stresses in order to enhance the collapse strengthfollowing radial expansion and plastic deformation.

In several exemplary experimental embodiments, reducing residualstresses in samples of the tubular members prior to radial expansion andplastic deformation increased the collapse strength of the radiallyexpanded and plastically deformed tubular members.

In several exemplary experimental embodiments, the collapse strength ofradially expanded and plastically deformed samples of the tubulars weredetermined on an as-received basis, after strain aging at 250 F for 5hours to reduce residual stresses, and after strain aging at 350 F for14 days to reduce residual stresses as follows: Collapse Strength AfterTubular Sample 10% Radial Expansion Tubular Sample 1-as received from4000 psi manufacturer Tubular Sample 1-strain aged at 250 F. for 4800psi 5 hours to reduce residual stresses Tubular Sample 1-strain aged at350 F. for 5000 psi 14 days to reduce residual stresses

As indicated by the above table, reducing residual stresses in thetubular members, prior to radial expansion and plastic deformation,significantly increased the resulting collapse strength—post expansion.

In several exemplary experimental embodiments, the collapse strength ofradially expanded and plastically deformed samples of the tubulars weredetermined on an as-received basis, after strain aging at 250 F for 5hours to reduce residual stresses, and after strain aging at 350 F for14 days to reduce residual stresses as follows: Collapse Strength AfterTubular Sample 20% Radial Expansion Tubular Sample 1-as received from3000 psi manufacturer Tubular Sample 1-strain aged at 250 F. 4000 psifor 5 hours to reduce residual stresses Tubular Sample 1-strain aged at350 F. 4250 psi for 14 days to reduce residual stresses

As indicated by the above table, reducing residual stresses in thetubular members, prior to radial expansion and plastic deformation,significantly increased the resulting collapse strength—post expansion.

In an exemplary experimental embodiment, residual stresses within atubular member were decreased from about −12,000 psi to about −6,000psi, a reduction of about 105%. As a result, the collapse strength ofthe resulting tubular member was increased from about 1550 psi to about1750 psi. This was an unexpected result.

In several exemplary experimental embodiments, tubular members wereradially expanded and plastically deformed using different lubricants toachieve a range of coefficients of friction between the tubular membersand a solid expansion cone during the radial expansion and plasticdeformation of the tubular members. As a result, the followingexperimental results were obtained: RATIO OF DIAMETER TO WALL THICKNESSWALL AFTER COLLAPSE COEFFICIENT EXPANSION THICKNESS EXPANSION STRENGTHSAMPLE OF FRICTION FORCE (lbf) (t) (D/t) (ksi) 1 0.125 145,900 0.30524.8 2,379 2 0.075 143,000 0.350 21.6 3,243 3 0.02 149,900 0.450 16.85,837 4 0.02 125,800 0.500 15.1 5,359 5 0.02 125,800 0.500 15.1 8,443The above tabular experimental results were unexpected. In particular,the resulting collapse strength of the radially expanded and plasticallydeformed tubular was increased by one or more of the following: 1)reducing the coefficient of friction; and/or 2) reducing the ratio ofD/t.

Referring to FIG. 103, in an exemplary experimental embodiment, a sampleof steel pipe, for which the normal manufacturing process was modifiedto include quenching and tempering (the “Quenched and Tempered SteelPipe No. 1”), was tested to generate a stress vs. strain curve 10300. Asillustrated in FIG. 103, the yield point of the curve 10300 was 76.8ksi. Further stress and strain testing of the Quenched and TemperedSteel Pipe No. 1, yielded the following characteristics: Wall WidthThickness Elongation Reduction Reduction Yield Yield/TensileLongitudinal % PRIOR % PRIOR Strength Strength % PRIOR TO TO Sample ksiRatio TO FAILURE FAILURE FAILURE Anisotropy Quenched 76.8 0.82 16% 32%45% 0.65 and Tempered Steel Pipe No. 1The testing results for the Quenched and Tempered Steel Pipe No. 1,illustrated in FIG. 103, and summarized above in tabular form wereunexpected results. Thus, the modification of the normal manufacturingprocess of the Quenched and Tempered Steel Pipe No. 1, to include aquenching and tempering step, significantly and unexpectedly, enhancedthe performance characteristics of the pipe thereby making the pipeparticularly suited to use as an expandable tubular.

Referring to FIG. 104, in an exemplary experimental embodiment, a sampleof 9⅝″ steel pipe, for which the normal manufacturing process wasmodified to include quenching and tempering (the “Quenched and TemperedSteel Pipe No. 2”), a sample of conventional 9⅝″ NT80-HE steel pipe fromNippon Steel, and a sample of conventional 9⅝″ NT55-HE steel pipe fromNippon Steel were tested to generate stress vs. strain curves 10400,10402, and 10404, for the Quenched and Tempered Steel Pipe No. 2, the9⅝″ NT80-HE steel pipe from Nippon Steel, and the 9⅝″ NT55-HE steel pipefrom Nippon Steel, respectively. As illustrated in FIG. 104, the yieldpoints of the curves 10400, 10402, and 10404, were 84.4 ksi, 61.5 ksi,and 73.7 ksi, respectively. Further stress and strain testing of theQuenched and Tempered Steel Pipe No. 2, the 9⅝″ NT80-HE steel pipe fromNippon Steel, and the 9⅝″ NT55-HE steel pipe from Nippon Steel, yieldedthe following characteristics: Wall Width Thickness Elongation ReductionReduction Yield Yield/Tensile Longitudinal % PRIOR % PRIOR StrengthStrength % PRIOR TO TO Sample ksi Ratio TO FAILURE FAILURE FAILUREAnisotropy Quenched 84.4 0.840 20.5% 40.0% 41.8% 0.935 and TemperedSteel Pipe No. 2 NT80-HE 61.5 0.62 16.5% 25.5%   47% 0.46 NT55-HE 73.70.67 13.5% 20.4% 37.5% 0.48The testing results for the Quenched and Tempered Steel Pipe No. 2,illustrated in FIG. 104, and summarized above in tabular form wereunexpected results. Thus, the modification of the normal manufacturingprocess of the Quenched and Tempered Steel Pipe No. 2, to include aquenching and tempering step, significantly and unexpectedly, enhancedthe performance characteristics of the pipe, relative to theconventional NT80-HE and NT55-HE pipes, thereby making the pipeparticularly suited to use as an expandable tubular.

In an exemplary experimental embodiment, samples of steel pipe, forwhich the normal manufacturing process was modified to include quenchingand tempering (the “Quenched and Tempered Steel Pipe Nos. 3 and 4”),were stress and strain tested and exhibited the followingcharacteristics: Value Quenched Quenched and and Tempered Tempered SteelPipe Steel Pipe Characteristic No.3 No.4 YIELD STRENGTH 81.25 ksi 78.77ksi Y/T RATIO 0.829 0.822 ELONGATION PRIOR TO 14.88% 15.90% FAILUREWIDTH REDUCTION PRIOR TO 37.8% 44.0% FAILURE WALL THICKNESS 43.25%43.33% REDUCTION PRIOR TO FAILURE ANISOTROPY 0.830 1.03The tabular experimental results presented above were unexpected.

In an exemplary experimental embodiment, samples of steel pipe, forwhich the normal manufacturing process was modified to include quenchingand tempering (the “Quenched and Tempered Steel Pipe No. 5”), werestress and strain tested and exhibited the following characteristics:Characteristic Value YIELD STRENGTH 80.19 ksi Y/T RATIO 0.826 ELONGATIONPRIOR TO 15.25% FAILURE WIDTH REDUCTION PRIOR TO 40.4% FAILURE WALLTHICKNESS 43.3% REDUCTION PRIOR TO FAILURE ANISOTROPY 0.915The tabular experimental results presented above were unexpected.

In an exemplary experimental embodiment, a sample of steel pipe, forwhich the normal manufacturing process was modified to include quenchingand tempering (the “Quenched and Tempered Steel Pipe Nos. 6 and 7”), asample of conventional NT80-HE steel pipe from Nippon Steel, and asample of conventional NT55-HE steel pipe from Nippon Steel were testedto determine absorbed energy and flare expansion characteristics andexhibited the following characteristics: Value Quenched Quenched and andTempered Tempered Steel Pipe Steel Pipe Characteristic No. 6 No. 7NT80-HE NT55-HE ABSORBED 125 ft-lbs 145 ft-lbs 100 ft-lbs 50 ft-lbsENERGY- LONGITUDINAL ABSORBED  59 ft-lbs  59 ft-lbs  40 ft-lbs 30 ft-lbsENERGY- TRANSVERSE ABSORBED 176 ft-lbs 174 ft-lbs  70 ft-lbs  4 ft-lbsENERGY-WELD FLARE EXPANSION 42% 52% 32% 30%The testing results for the Quenched and Tempered Steel Pipe Nos. 6 and7 summarized above in tabular form were unexpected results. Thus, themodification of the normal manufacturing process of the Quenched andTempered Steel Pipe Nos. 6 and 7, to include a quenching and temperingstep, significantly and unexpectedly, enhanced the performancecharacteristics of the pipe, relative to the conventional NT80-HE andNT55-HE pipes, thereby making the Quenched and Tempered Pipesparticularly suited to use as an expandable tubular.

In an exemplary embodiment, the flare expansion of the Quenched andTempered Steel Pipe Nos. 6 and 7, the sample of conventional NT80-HEsteel pipe from Nippon Steel, and the sample of conventional NT55-HEsteel pipe from Nippon Steel were performed by pressing a tapered solidexpansion cone into an end of the pipe samples to radially expand andplastically deform the ends of the pipe samples.

In an exemplary experimental embodiment, samples of steel pipe, forwhich the normal manufacturing process was modified to include quenchingand tempering (the “Quenched and Tempered Steel Pipe No. 8”), werestress and strain tested and exhibited the following characteristics:Characteristic Value YIELD STRENGTH 88.8 ksi Y/T RATIO 0.86 ELONGATIONPRIOR TO 22% FAILURE WIDTH REDUCTION PRIOR TO 39% FAILURE WALL THICKNESS41% REDUCTION PRIOR TO FAILURE ANISOTROPY 0.93The tabular experimental results presented above were unexpected.

In an exemplary experimental embodiment, a sample of steel pipe, forwhich the normal manufacturing process was modified to include quenchingand tempering (the “Quenched and Tempered Steel Pipe No. 9”), a sampleof conventional NT80-HE steel pipe from Nippon Steel, and a sample ofconventional NT55-HE steel pipe from Nippon Steel were tested todetermine absorbed energy and flare expansion characteristics andexhibited the following characteristics: Value Quenched and TemperedSteel Characteristic Pipe No. 9 NT80-HE NT55-HE YIELD STRENGTH 84.4 ksi73.7 ksi 61.5 ksi YIELD/TENSILE 0.840 0.67 0.62 STRENGTH RATIOELONGATION 20.5% 13.5% 16.5% BEFORE FAILURE WIDTH REDUCTION 40.0% 20.4%25.5% BEFORE FAILURE WALL THICKNESS 41.8% 37.5% 47% REDUCTION BEFOREFAILURE ANISOTROPY 0.935 0.48 0.46The testing results for the Quenched and Tempered Steel Pipe No. 9summarized above in tabular form were unexpected results. Thus, themodification of the normal manufacturing process of the Quenched andTempered Steel Pipe No. 9, to include a quenching and tempering step,significantly and unexpectedly, enhanced the performance characteristicsof the pipe, relative to the conventional NT80-HE and NT55-HE pipes,thereby making the Quenched and Tempered Pipes particularly suited touse as an expandable tubular.

In an exemplary experimental embodiment, samples of steel pipe, forwhich the normal manufacturing process was modified to include quenchingand tempering (the “Quenched and Tempered Steel Pipe No. 10”), werestress and strain tested and exhibited the following characteristics:Characteristic Value YIELD STRENGTH 84.6 ksi Y/T RATIO 0.85 ELONGATIONPRIOR TO 21% FAILURE WIDTH REDUCTION PRIOR TO 39% FAILURE WALL THICKNESS43% REDUCTION PRIOR TO FAILURE ANISOTROPY 0.88The tabular experimental results presented above were unexpected.

In an exemplary embodiment, the composition of the Quench and TemperSteel Pipe Nos. 1 to 10 included the following weight percentages: C SiMn P S Cu Cr Ni 0.27 0.14 1.28 0.009 0.005 0.14In an exemplary embodiment, the quenching of the Quench and Temper SteelPipe Nos. 1 to 10 was provided at 970 C, and the tempering of the Quenchand Temper Steel Pipe Nos. 1 to 10 was provided for 10 minutes at 670 C.

In an exemplary embodiment, using a combination of empirical,theoretical, and experimental data, electrical resistance pipe (“ERW”)tubular members most suitable for radial expansion and plasticdeformation exhibit the following characteristics: Characteristic ValueABSORBED ENERGY IN THE at least 80 ft-lb LONGITUDINAL DIRECTION ABSORBEDENERGY IN THE at least 60 ft-lb TRANSVERSE DIRECTION ABSORBED ENERGY INTHE at least 60 ft-lb TRANSVERSE WELD AREA FLARE EXPANSION 45% to 75%MINIMUM W/O CRACKS TENSILE STRENGTH 60 TO 120 ksi YIELD STRENGTH 40 TO100 ksi Y/T RATIO 40% to 85% MAXIMUM LONGITUDINAL ELONGATION PRIOR TO AMINIMUM OF 22% to 35% FAILURE WIDTH REDUCTION PRIOR TO FAILURE A MINIMUMOF 30% to 45% WALL THICKNESS REDUCTION PRIOR A MINIMUM OF 30% to 45% TOFAILURE ANISOTROPY A MINIMUM OF 0.8 to 1.5

In an exemplary experimental embodiment, based upon theoretical,empirical, and experimental data, tubular members that exhibit thefollowing characteristics are best suited for radial expansion andplastic deformation: Characteristic Value YIELD STRENGTH 50 to 95 ksiY/T RATIO less than 0.5 to 0.82 ELONGATION PRIOR TO greater than 16 to30% FAILURE WIDTH REDUCTION PRIOR TO greater than 32 to 45% FAILURE WALLTHICKNESS greater than 30 to 45% REDUCTION PRIOR TO FAILURE ANISOTROPYgreater than 0.65 to 1.5

In an exemplary embodiment, as illustrated in FIGS. 105 and 106, in anexemplary embodiment, a method 10500 of processing tubular members isimplemented in which, in step 10502, a manufactured tubular member 10502a is received. In step 10504, the manufactured tubular member 10502 a isthen cold rolled to provide a cold-rolled tubular member 10504 a. Instep 10506, the cold-rolled tubular member 10504 a is then intercritical annealed to provide an annealed tubular member 10506 a. In step10508, the annealed tubular member 10506 a is then positioned within awellbore and radially expanded and plastically deformed in aconventional manner to provide a radially expanded and plasticallydeformed tubular member 10508 a. In step 10510, the radially expandedand plastically deformed tubular member 10508 a is then baked within thewellbore, using the ambient temperatures within the wellbore, to providean after-baked tubular member 10510 a. As illustrated in FIG. 106, theultimate and final yield strength of the after-baked tubular member10510 a is greater than the yield strength of the manufactured tubularmember 10502 a. In an exemplary embodiment, the manufactured tubularmember 10502 a is a dual phase steel pipe or a Transformation InducedPlasticity (“TRIP”) steel pipe.

In an exemplary embodiment, the dual phase steel manufactured pipe 10502a includes a microstructure having about 15% to 30% martensite andferrite. In an exemplary embodiment, the dual phase steel manufacturedpipe 10502 a includes a composition of 0.1% C, 1.2% Mn, and 0.3% Si.

In an exemplary embodiment, as illustrated in FIG. 107, when themanufactured pipe 10502 a is a dual phase steel, the initialmicrostructure of the pipe includes ferrite and pearlite. In anexemplary embodiment, in step 10506, the intercritical annealing of thecold rolled pipe 10504 a is performed at about 75° C. As a result of theintercritical annealing, at least some of the pearlite is converted toaustentite. Following the completion of the intercritical annealing instep 10506, the annealed pipe 10506 a is allowed to cool. As a result ofthe cooling, at least some of the austentite in the annealed pipe 10506a is converted to martensite. In an exemplary embodiment, in step 10510,the baking of the radially expanded and plastically deformed pipe 10508a is provided within the wellbore at temperatures ranging from about 100C to 250 C. In an exemplary embodiment, as a result of the baking step10510, the radially expanded and plastically deformed pipe 10508 a isstress-relieved and bake hardened.

In an exemplary embodiment, in step 10504 of the method 10500, asillustrated in FIG. 108, the temperature of the manufactured steel pipe10502 a follows a curve 10802 in which the steel pipe is deformedthroughout the cooling progression of the curve at a plurality ofseparate stages, 10802 a and 10802 b. In an exemplary embodiment, duringthe first pipe rolling stage 10802 a, insoluble precipitates within thepipe 10502 a retard austentite growth and the deformation also promotesprecipitation. In an exemplary embodiment, during the second piperolling state 10802 b, insoluble precipitates within the pipe 10502 ainhibit recrystallization and austentite grains are conditioned. As aresult, the ultimate yield and collapse strength of the baked pipe 10510a is enhanced.

In several exemplary embodiments, the teachings of the presentdisclosure are combined with one or more of the teachings disclosed inFR 2 841 626, filed on Jun. 28, 2002, and published on Jan. 2, 2004, thedisclosure of which is incorporated herein by reference.

A method of forming a tubular liner within a preexisting structure isprovided that includes positioning a tubular assembly within thepreexisting structure; and radially expanding and plastically deformingthe tubular assembly within the preexisting structure, wherein, prior tothe radial expansion and plastic deformation of the tubular assembly, apredetermined portion of the tubular assembly has a lower yield pointthan another portion of the tubular assembly. In an exemplaryembodiment, the predetermined portion of the tubular assembly has ahigher ductility and a lower yield point prior to the radial expansionand plastic deformation than after the radial expansion and plasticdeformation. In an exemplary embodiment, the predetermined portion ofthe tubular assembly has a higher ductility prior to the radialexpansion and plastic deformation than after the radial expansion andplastic deformation. In an exemplary embodiment, the predeterminedportion of the tubular assembly has a lower yield point prior to theradial expansion and plastic deformation than after the radial expansionand plastic deformation. In an exemplary embodiment, the predeterminedportion of the tubular assembly has a larger inside diameter after theradial expansion and plastic deformation than other portions of thetubular assembly. In an exemplary embodiment, the method furtherincludes positioning another tubular assembly within the preexistingstructure in overlapping relation to the tubular assembly; and radiallyexpanding and plastically deforming the other tubular assembly withinthe preexisting structure, wherein, prior to the radial expansion andplastic deformation of the tubular assembly, a predetermined portion ofthe other tubular assembly has a lower yield point than another portionof the other tubular assembly. In an exemplary embodiment, the insidediameter of the radially expanded and plastically deformed other portionof the tubular assembly is equal to the inside diameter of the radiallyexpanded and plastically deformed other portion of the other tubularassembly. In an exemplary embodiment, the predetermined portion of thetubular assembly includes an end portion of the tubular assembly. In anexemplary embodiment, the predetermined portion of the tubular assemblyincludes a plurality of predetermined portions of the tubular assembly.In an exemplary embodiment, the predetermined portion of the tubularassembly includes a plurality of spaced apart predetermined portions ofthe tubular assembly. In an exemplary embodiment, the other portion ofthe tubular assembly includes an end portion of the tubular assembly. Inan exemplary embodiment, the other portion of the tubular assemblyincludes a plurality of other portions of the tubular assembly. In anexemplary embodiment, the other portion of the tubular assembly includesa plurality of spaced apart other portions of the tubular assembly. Inan exemplary embodiment, the tubular assembly includes a plurality oftubular members coupled to one another by corresponding tubularcouplings. In an exemplary embodiment, the tubular couplings include thepredetermined portions of the tubular assembly; and wherein the tubularmembers comprise the other portion of the tubular assembly. In anexemplary embodiment, one or more of the tubular couplings include thepredetermined portions of the tubular assembly. In an exemplaryembodiment, one or more of the tubular members include the predeterminedportions of the tubular assembly. In an exemplary embodiment, thepredetermined portion of the tubular assembly defines one or moreopenings. In an exemplary embodiment, one or more of the openingsinclude slots. In an exemplary embodiment, the anisotropy for thepredetermined portion of the tubular assembly is greater than 1. In anexemplary embodiment, the anisotropy for the predetermined portion ofthe tubular assembly is greater than 1. In an exemplary embodiment, thestrain hardening exponent for the predetermined portion of the tubularassembly is greater than 0.12. In an exemplary embodiment, theanisotropy for the predetermined portion of the tubular assembly isgreater than 1; and the strain hardening exponent for the predeterminedportion of the tubular assembly is greater than 0.12. In an exemplaryembodiment, the predetermined portion of the tubular assembly is a firststeel alloy including: 0.065% C, 1.44% Mn, 0.01% P, 0.002% S, 0.24% Si,0.01% Cu, 0.01% Ni, and 0.02% Cr. In an exemplary embodiment, the yieldpoint of the predetermined portion of the tubular assembly is at mostabout 46.9 ksi prior to the radial expansion and plastic deformation;and the yield point of the predetermined portion of the tubular assemblyis at least about 65.9 ksi after the radial expansion and plasticdeformation. In an exemplary embodiment, the yield point of thepredetermined portion of the tubular assembly after the radial expansionand plastic deformation is at least about 40% greater than the yieldpoint of the predetermined portion of the tubular assembly prior to theradial expansion and plastic deformation. In an exemplary embodiment,the anisotropy of the predetermined portion of the tubular assembly,prior to the radial expansion and plastic deformation, is about 1.48. Inan exemplary embodiment, the predetermined portion of the tubularassembly includes a second steel alloy including: 0.18% C, 1.28% Mn,0.017% P, 0.004% S, 0.29% Si, 0.01% Cu, 0.01% Ni, and 0.03% Cr. In anexemplary embodiment, the yield point of the predetermined portion ofthe tubular assembly is at most about 57.8 ksi prior to the radialexpansion and plastic deformation; and the yield point of thepredetermined portion of the tubular assembly is at least about 74.4 ksiafter the radial expansion and plastic deformation. In an exemplaryembodiment, the yield point of the predetermined portion of the tubularassembly after the radial expansion and plastic deformation is at leastabout 28% greater than the yield point of the predetermined portion ofthe tubular assembly prior to the radial expansion and plasticdeformation. In an exemplary embodiment, the anisotropy of thepredetermined portion of the tubular assembly, prior to the radialexpansion and plastic deformation, is about 1.04. In an exemplaryembodiment, the predetermined portion of the tubular assembly includes athird steel alloy including: 0.08% C, 0.82% Mn, 0.006% P, 0.003% S,0.30% Si, 0.16% Cu, 0.05% Ni, and 0.05% Cr. In an exemplary embodiment,the anisotropy of the predetermined portion of the tubular assembly,prior to the radial expansion and plastic deformation, is about 1.92. Inan exemplary embodiment, the predetermined portion of the tubularassembly includes a fourth steel alloy including: 0.02% C, 1.31% Mn,0.02% P, 0.001% S, 0.45% Si, 9.1% Ni, and 18.7% Cr. In an exemplaryembodiment, the anisotropy of the predetermined portion of the tubularassembly, prior to the radial expansion and plastic deformation, isabout 1.34. In an exemplary embodiment, the yield point of thepredetermined portion of the tubular assembly is at most about 46.9 ksiprior to the radial expansion and plastic deformation; and wherein theyield point of the predetermined portion of the tubular assembly is atleast about 65.9 ksi after the radial expansion and plastic deformation.In an exemplary embodiment, the yield point of the predetermined portionof the tubular assembly after the radial expansion and plasticdeformation is at least about 40% greater than the yield point of thepredetermined portion of the tubular assembly prior to the radialexpansion and plastic deformation. In an exemplary embodiment, theanisotropy of the predetermined portion of the tubular assembly, priorto the radial expansion and plastic deformation, is at least about 1.48.In an exemplary embodiment, the yield point of the predetermined portionof the tubular assembly is at most about 57.8 ksi prior to the radialexpansion and plastic deformation; and the yield point of thepredetermined portion of the tubular assembly is at least about 74.4 ksiafter the radial expansion and plastic deformation. In an exemplaryembodiment, the yield point of the predetermined portion of the tubularassembly after the radial expansion and plastic deformation is at leastabout 28% greater than the yield point of the predetermined portion ofthe tubular assembly prior to the radial expansion and plasticdeformation. In an exemplary embodiment, the anisotropy of thepredetermined portion of the tubular assembly, prior to the radialexpansion and plastic deformation, is at least about 1.04. In anexemplary embodiment, the anisotropy of the predetermined portion of thetubular assembly, prior to the radial expansion and plastic deformation,is at least about 1.92. In an exemplary embodiment, the anisotropy ofthe predetermined portion of the tubular assembly, prior to the radialexpansion and plastic deformation, is at least about 1.34. In anexemplary embodiment, the anisotropy of the predetermined portion of thetubular assembly, prior to the radial expansion and plastic deformation,ranges from about 1.04 to about 1.92. In an exemplary embodiment, theyield point of the predetermined portion of the tubular assembly, priorto the radial expansion and plastic deformation, ranges from about 47.6ksi to about 61.7 ksi. In an exemplary embodiment, the expandabilitycoefficient of the predetermined portion of the tubular assembly, priorto the radial expansion and plastic deformation, is greater than 0.12.In an exemplary embodiment, the expandability coefficient of thepredetermined portion of the tubular assembly is greater than theexpandability coefficient of the other portion of the tubular assembly.In an exemplary embodiment, the tubular assembly includes a wellborecasing, a pipeline, or a structural support. In an exemplary embodiment,the carbon content of the predetermined portion of the tubular assemblyis less than or equal to 0.12 percent; and wherein the carbon equivalentvalue for the predetermined portion of the tubular assembly is less than0.21. In an exemplary embodiment, the carbon content of thepredetermined portion of the tubular assembly is greater than 0.12percent; and wherein the carbon equivalent value for the predeterminedportion of the tubular assembly is less than 0.36. In an exemplaryembodiment, a yield point of an inner tubular portion of at least aportion of the tubular assembly is less than a yield point of an outertubular portion of the portion of the tubular assembly. In an exemplaryembodiment, yield point of the inner tubular portion of the tubular bodyvaries as a function of the radial position within the tubular body. Inan exemplary embodiment, the yield point of the inner tubular portion ofthe tubular body varies in an linear fashion as a function of the radialposition within the tubular body. In an exemplary embodiment, the yieldpoint of the inner tubular portion of the tubular body varies in annon-linear fashion as a function of the radial position within thetubular body. In an exemplary embodiment, the yield point of the outertubular portion of the tubular body varies as a function of the radialposition within the tubular body. In an exemplary embodiment, the yieldpoint of the outer tubular portion of the tubular body varies in anlinear fashion as a function of the radial position within the tubularbody. In an exemplary embodiment, the yield point of the outer tubularportion of the tubular body varies in an non-linear fashion as afunction of the radial position within the tubular body. In an exemplaryembodiment, the yield point of the inner tubular portion of the tubularbody varies as a function of the radial position within the tubularbody; and wherein the yield point of the outer tubular portion of thetubular body varies as a function of the radial position within thetubular body. In an exemplary embodiment, the yield point of the innertubular portion of the tubular body varies in a linear fashion as afunction of the radial position within the tubular body; and wherein theyield point of the outer tubular portion of the tubular body varies in alinear fashion as a function of the radial position within the tubularbody. In an exemplary embodiment, the yield point of the inner tubularportion of the tubular body varies in a linear fashion as a function ofthe radial position within the tubular body; and wherein the yield pointof the outer tubular portion of the tubular body varies in a non-linearfashion as a function of the radial position within the tubular body. Inan exemplary embodiment, the yield point of the inner tubular portion ofthe tubular body varies in a non-linear fashion as a function of theradial position within the tubular body; and wherein the yield point ofthe outer tubular portion of the tubular body varies in a linear fashionas a function of the radial position within the tubular body. In anexemplary embodiment, the yield point of the inner tubular portion ofthe tubular body varies in a non-linear fashion as a function of theradial position within the tubular body; and wherein the yield point ofthe outer tubular portion of the tubular body varies in a non-linearfashion as a function of the radial position within the tubular body. Inan exemplary embodiment, the rate of change of the yield point of theinner tubular portion of the tubular body is different than the rate ofchange of the yield point of the outer tubular portion of the tubularbody. In an exemplary embodiment, the rate of change of the yield pointof the inner tubular portion of the tubular body is different than therate of change of the yield point of the outer tubular portion of thetubular body. In an exemplary embodiment, prior to the radial expansionand plastic deformation, at least a portion of the tubular assemblycomprises a microstructure comprising a hard phase structure and a softphase structure. In an exemplary embodiment, prior to the radialexpansion and plastic deformation, at least a portion of the tubularassembly comprises a microstructure comprising a transitional phasestructure. In an exemplary embodiment, the hard phase structurecomprises martensite. In an exemplary embodiment, the soft phasestructure comprises ferrite. In an exemplary embodiment, thetransitional phase structure comprises retained austentite. In anexemplary embodiment, the hard phase structure comprises martensite;wherein the soft phase structure comprises ferrite; and wherein thetransitional phase structure comprises retained austentite. In anexemplary embodiment, the portion of the tubular assembly comprising amicrostructure comprising a hard phase structure and a soft phasestructure comprises, by weight percentage, about 0.1% C, about 1.2% Mn,and about 0.3% Si.

An expandable tubular member has been described that includes a steelalloy including: 0.065% C, 1.44% Mn, 0.01% P, 0.002% S, 0.24% Si, 0.01%Cu, 0.01% Ni, and 0.02% Cr. In an exemplary embodiment, a yield point ofthe tubular member is at most about 46.9 ksi prior to a radial expansionand plastic deformation; and a yield point of the tubular member is atleast about 65.9 ksi after the radial expansion and plastic deformation.In an exemplary embodiment, the yield point of the tubular member afterthe radial expansion and plastic deformation is at least about 40%greater than the yield point of the tubular member prior to the radialexpansion and plastic deformation. In an exemplary embodiment, theanisotropy of the tubular member, prior to a radial expansion andplastic deformation, is about 1.48. In an exemplary embodiment, thetubular member includes a wellbore casing, a pipeline, or a structuralsupport.

An expandable tubular member has been described that includes a steelalloy including: 0.18% C, 1.28% Mn, 0.017% P, 0.004% S, 0.29% Si, 0.01%Cu, 0.01% Ni, and 0.03% Cr. In an exemplary embodiment, a yield point ofthe tubular member is at most about 57.8 ksi prior to a radial expansionand plastic deformation; and the yield point of the tubular member is atleast about 74.4 ksi after the radial expansion and plastic deformation.In an exemplary embodiment, a yield point of the of the tubular memberafter a radial expansion and plastic deformation is at least about 28%greater than the yield point of the tubular member prior to the radialexpansion and plastic deformation. In an exemplary embodiment, theanisotropy of the tubular member, prior to a radial expansion andplastic deformation, is about 1.04. In an exemplary embodiment, thetubular member includes a wellbore casing, a pipeline, or a structuralsupport.

An expandable tubular member has been described that includes a steelalloy including: 0.08% C, 0.82% Mn, 0.006% P, 0.003% S, 0.30% Si, 0.16%Cu, 0.05% Ni, and 0.05% Cr. In an exemplary embodiment, the anisotropyof the tubular member, prior to a radial expansion and plasticdeformation, is about 1.92. In an exemplary embodiment, the tubularmember includes a wellbore casing, a pipeline, or a structural support.

An expandable tubular member has been described that includes a steelalloy including: 0.02% C, 1.31% Mn, 0.02% P, 0.001% S, 0.45% Si, 9.1%Ni, and 18.7% Cr. In an exemplary embodiment, the anisotropy of thetubular member, prior to a radial expansion and plastic deformation, isabout 1.34. In an exemplary embodiment, the tubular member includes awellbore casing, a pipeline, or a structural support.

An expandable tubular member has been described, wherein the yield pointof the expandable tubular member is at most about 46.9 ksi prior to aradial expansion and plastic deformation; and wherein the yield point ofthe expandable tubular member is at least about 65.9 ksi after theradial expansion and plastic deformation. In an exemplary embodiment,the tubular member includes a wellbore casing, a pipeline, or astructural support.

An expandable tubular member has been described, wherein a yield pointof the expandable tubular member after a radial expansion and plasticdeformation is at least about 40% greater than the yield point of theexpandable tubular member prior to the radial expansion and plasticdeformation. In an exemplary embodiment, the tubular member includes awellbore casing, a pipeline, or a structural support.

An expandable tubular member has been described, wherein the anisotropyof the expandable tubular member, prior to the radial expansion andplastic deformation, is at least about 1.48. In an exemplary embodiment,the tubular member includes a wellbore casing, a pipeline, or astructural support.

An expandable tubular member has been described, wherein the yield pointof the expandable tubular member is at most about 57.8 ksi prior to theradial expansion and plastic deformation; and wherein the yield point ofthe expandable tubular member is at least about 74.4 ksi after theradial expansion and plastic deformation. In an exemplary embodiment,the tubular member includes a wellbore casing, a pipeline, or astructural support.

An expandable tubular member has been described, wherein the yield pointof the expandable tubular member after a radial expansion and plasticdeformation is at least about 28% greater than the yield point of theexpandable tubular member prior to the radial expansion and plasticdeformation. In an exemplary embodiment, the tubular member includes awellbore casing, a pipeline, or a structural support.

An expandable tubular member has been described, wherein the anisotropyof the expandable tubular member, prior to the radial expansion andplastic deformation, is at least about 1.04. In an exemplary embodiment,the tubular member includes a wellbore casing, a pipeline, or astructural support.

An expandable tubular member has been described, wherein the anisotropyof the expandable tubular member, prior to the radial expansion andplastic deformation, is at least about 1.92. In an exemplary embodiment,the tubular member includes a wellbore casing, a pipeline, or astructural support.

An expandable tubular member has been described, wherein the anisotropyof the expandable tubular member, prior to the radial expansion andplastic deformation, is at least about 1.34. In an exemplary embodiment,the tubular member includes a wellbore casing, a pipeline, or astructural support.

An expandable tubular member has been described, wherein the anisotropyof the expandable tubular member, prior to the radial expansion andplastic deformation, ranges from about 1.04 to about 1.92. In anexemplary embodiment, the tubular member includes a wellbore casing, apipeline, or a structural support.

An expandable tubular member has been described, wherein the yield pointof the expandable tubular member, prior to the radial expansion andplastic deformation, ranges from about 47.6 ksi to about 61.7 ksi. In anexemplary embodiment, the tubular member includes a wellbore casing, apipeline, or a structural support.

An expandable tubular member has been described, wherein theexpandability coefficient of the expandable tubular member, prior to theradial expansion and plastic deformation, is greater than 0.12. In anexemplary embodiment, the tubular member includes a wellbore casing, apipeline, or a structural support.

An expandable tubular member has been described, wherein theexpandability coefficient of the expandable tubular member is greaterthan the expandability coefficient of another portion of the expandabletubular member. In an exemplary embodiment, the tubular member includesa wellbore casing, a pipeline, or a structural support.

An expandable tubular member has been described, wherein the tubularmember has a higher ductility and a lower yield point prior to a radialexpansion and plastic deformation than after the radial expansion andplastic deformation. In an exemplary embodiment, the tubular memberincludes a wellbore casing, a pipeline, or a structural support.

A method of radially expanding and plastically deforming a tubularassembly including a first tubular member coupled to a second tubularmember has been described that includes radially expanding andplastically deforming the tubular assembly within a preexistingstructure; and using less power to radially expand each unit length ofthe first tubular member than to radially expand each unit length of thesecond tubular member. In an exemplary embodiment, the tubular memberincludes a wellbore casing, a pipeline, or a structural support.

A system for radially expanding and plastically deforming a tubularassembly including a first tubular member coupled to a second tubularmember has been described that includes means for radially expanding thetubular assembly within a preexisting structure; and means for usingless power to radially expand each unit length of the first tubularmember than required to radially expand each unit length of the secondtubular member. In an exemplary embodiment, the tubular member includesa wellbore casing, a pipeline, or a structural support.

A method of manufacturing a tubular member has been described thatincludes processing a tubular member until the tubular member ischaracterized by one or more intermediate characteristics; positioningthe tubular member within a preexisting structure; and processing thetubular member within the preexisting structure until the tubular memberis characterized one or more final characteristics. In an exemplaryembodiment, the tubular member includes a wellbore casing, a pipeline,or a structural support. In an exemplary embodiment, the preexistingstructure includes a wellbore that traverses a subterranean formation.In an exemplary embodiment, the characteristics are selected from agroup consisting of yield point and ductility. In an exemplaryembodiment, processing the tubular member within the preexistingstructure until the tubular member is characterized one or more finalcharacteristics includes: radially expanding and plastically deformingthe tubular member within the preexisting structure.

An apparatus has been described that includes an expandable tubularassembly; and an expansion device coupled to the expandable tubularassembly; wherein a predetermined portion of the expandable tubularassembly has a lower yield point than another portion of the expandabletubular assembly. In an exemplary embodiment, the expansion deviceincludes a rotary expansion device, an axially displaceable expansiondevice, a reciprocating expansion device, a hydroforming expansiondevice, and/or an impulsive force expansion device. In an exemplaryembodiment, the predetermined portion of the tubular assembly has ahigher ductility and a lower yield point than another portion of theexpandable tubular assembly. In an exemplary embodiment, thepredetermined portion of the tubular assembly has a higher ductilitythan another portion of the expandable tubular assembly. In an exemplaryembodiment, the predetermined portion of the tubular assembly has alower yield point than another portion of the expandable tubularassembly. In an exemplary embodiment, the predetermined portion of thetubular assembly includes an end portion of the tubular assembly. In anexemplary embodiment, the predetermined portion of the tubular assemblyincludes a plurality of predetermined portions of the tubular assembly.In an exemplary embodiment, the predetermined portion of the tubularassembly includes a plurality of spaced apart predetermined portions ofthe tubular assembly. In an exemplary embodiment, the other portion ofthe tubular assembly includes an end portion of the tubular assembly. Inan exemplary embodiment, the other portion of the tubular assemblyincludes a plurality of other portions of the tubular assembly. In anexemplary embodiment, the other portion of the tubular assembly includesa plurality of spaced apart other portions of the tubular assembly. Inan exemplary embodiment, the tubular assembly includes a plurality oftubular members coupled to one another by corresponding tubularcouplings. In an exemplary embodiment, the tubular couplings comprisethe predetermined portions of the tubular assembly; and wherein thetubular members comprise the other portion of the tubular assembly. Inan exemplary embodiment, one or more of the tubular couplings comprisethe predetermined portions of the tubular assembly. In an exemplaryembodiment, one or more of the tubular members comprise thepredetermined portions of the tubular assembly. In an exemplaryembodiment, the predetermined portion of the tubular assembly definesone or more openings. In an exemplary embodiment, one or more of theopenings comprise slots. In an exemplary embodiment, the anisotropy forthe predetermined portion of the tubular assembly is greater than 1 Inan exemplary embodiment, the anisotropy for the predetermined portion ofthe tubular assembly is greater than 1. In an exemplary embodiment, thestrain hardening exponent for the predetermined portion of the tubularassembly is greater than 0.12. In an exemplary embodiment, theanisotropy for the predetermined portion of the tubular assembly isgreater than 1; and wherein the strain hardening exponent for thepredetermined portion of the tubular assembly is greater than 0.12. Inan exemplary embodiment, the predetermined portion of the tubularassembly includes a first steel alloy including: 0.065% C, 1.44% Mn,0.01% P, 0.002% S, 0.24% Si, 0.01% Cu, 0.01% Ni, and 0.02% Cr. In anexemplary embodiment, the yield point of the predetermined portion ofthe tubular assembly is at most about 46.9 ksi. In an exemplaryembodiment, the anisotropy of the predetermined portion of the tubularassembly is about 1.48. In an exemplary embodiment, the predeterminedportion of the tubular assembly includes a second steel alloy including:0.18% C, 1.28% Mn, 0.017% P, 0.004% S, 0.29% Si, 0.01% Cu, 0.01% Ni, and0.03% Cr. In an exemplary embodiment, the yield point of thepredetermined portion of the tubular assembly is at most about 57.8 ksi.In an exemplary embodiment, the anisotropy of the predetermined portionof the tubular assembly is about 1.04. In an exemplary embodiment, thepredetermined portion of the tubular assembly includes a third steelalloy including: 0.08% C, 0.82% Mn, 0.006% P, 0.003% S, 0.30% Si, 0.16%Cu, 0.05% Ni, and 0.05% Cr. In an exemplary embodiment, the anisotropyof the predetermined portion of the tubular assembly is about 1.92. Inan exemplary embodiment, the predetermined portion of the tubularassembly includes a fourth steel alloy including: 0.02% C, 1.31% Mn,0.02% P, 0.001% S, 0.45% Si, 9.1% Ni, and 18.7% Cr. In an exemplaryembodiment, the anisotropy of the predetermined portion of the tubularassembly is at least about 1.34. In an exemplary embodiment, the yieldpoint of the predetermined portion of the tubular assembly is at mostabout 46.9 ksi. In an exemplary embodiment, the anisotropy of thepredetermined portion of the tubular assembly is at least about 1.48. Inan exemplary embodiment, the yield point of the predetermined portion ofthe tubular assembly is at most about 57.8 ksi. In an exemplaryembodiment, the anisotropy of the predetermined portion of the tubularassembly is at least about 1.04. In an exemplary embodiment, theanisotropy of the predetermined portion of the tubular assembly is atleast about 1.92. In an exemplary embodiment, the anisotropy of thepredetermined portion of the tubular assembly is at least about 1.34. Inan exemplary embodiment, the anisotropy of the predetermined portion ofthe tubular assembly ranges from about 1.04 to about 1.92. In anexemplary embodiment, the yield point of the predetermined portion ofthe tubular assembly ranges from about 47.6 ksi to about 61.7 ksi. In anexemplary embodiment, the expandability coefficient of the predeterminedportion of the tubular assembly is greater than 0.12. In an exemplaryembodiment, the expandability coefficient of the predetermined portionof the tubular assembly is greater than the expandability coefficient ofthe other portion of the tubular assembly. In an exemplary embodiment,the tubular assembly includes a wellbore casing, a pipeline, or astructural support. In an exemplary embodiment, the carbon content ofthe predetermined portion of the tubular assembly is less than or equalto 0.12 percent; and wherein the carbon equivalent value for thepredetermined portion of the tubular assembly is less than 0.21. In anexemplary embodiment, the carbon content of the predetermined portion ofthe tubular assembly is greater than 0.12 percent; and wherein thecarbon equivalent value for the predetermined portion of the tubularassembly is less than 0.36. In an exemplary embodiment, a yield point ofan inner tubular portion of at least a portion of the tubular assemblyis less than a yield point of an outer tubular portion of the portion ofthe tubular assembly. In an exemplary embodiment, the yield point of theinner tubular portion of the tubular body varies as a function of theradial position within the tubular body. In an exemplary embodiment, theyield point of the inner tubular portion of the tubular body varies inan linear fashion as a function of the radial position within thetubular body. In an exemplary embodiment, the yield point of the innertubular portion of the tubular body varies in an non-linear fashion as afunction of the radial position within the tubular body. In an exemplaryembodiment, the yield point of the outer tubular portion of the tubularbody varies as a function of the radial position within the tubularbody. In an exemplary embodiment, the yield point of the outer tubularportion of the tubular body varies in an linear fashion as a function ofthe radial position within the tubular body. In an exemplary embodiment,the yield point of the outer tubular portion of the tubular body variesin an non-linear fashion as a function of the radial position within thetubular body. In an exemplary embodiment, the yield point of the innertubular portion of the tubular body varies as a function of the radialposition within the tubular body; and wherein the yield point of theouter tubular portion of the tubular body varies as a function of theradial position within the tubular body. In an exemplary embodiment, theyield point of the inner tubular portion of the tubular body varies in alinear fashion as a function of the radial position within the tubularbody; and wherein the yield point of the outer tubular portion of thetubular body varies in a linear fashion as a function of the radialposition within the tubular body. In an exemplary embodiment, the yieldpoint of the inner tubular portion of the tubular body varies in alinear fashion as a function of the radial position within the tubularbody; and wherein the yield point of the outer tubular portion of thetubular body varies in a non-linear fashion as a function of the radialposition within the tubular body. In an exemplary embodiment, the yieldpoint of the inner tubular portion of the tubular body varies in anon-linear fashion as a function of the radial position within thetubular body; and wherein the yield point of the outer tubular portionof the tubular body varies in a linear fashion as a function of theradial position within the tubular body. In an exemplary embodiment, theyield point of the inner tubular portion of the tubular body varies in anon-linear fashion as a function of the radial position within thetubular body; and wherein the yield point of the outer tubular portionof the tubular body varies in a non-linear fashion as a function of theradial position within the tubular body. In an exemplary embodiment, therate of change of the yield point of the inner tubular portion of thetubular body is different than the rate of change of the yield point ofthe outer tubular portion of the tubular body. In an exemplaryembodiment, the rate of change of the yield point of the inner tubularportion of the tubular body is different than the rate of change of theyield point of the outer tubular portion of the tubular body. In anexemplary embodiment, at least a portion of the tubular assemblycomprises a microstructure comprising a hard phase structure and a softphase structure. In an exemplary embodiment, prior to the radialexpansion and plastic deformation, at least a portion of the tubularassembly comprises a microstructure comprising a transitional phasestructure. In an exemplary embodiment, wherein the hard phase structurecomprises martensite. In an exemplary embodiment, wherein the soft phasestructure comprises ferrite. In an exemplary embodiment, wherein thetransitional phase structure comprises retained austentite. In anexemplary embodiment, the hard phase structure comprises martensite;wherein the soft phase structure comprises ferrite; and wherein thetransitional phase structure comprises retained austentite. In anexemplary embodiment, the portion of the tubular assembly comprising amicrostructure comprising a hard phase structure and a soft phasestructure comprises, by weight percentage, about 0.1% C, about 1.2% Mn,and about 0.3% Si. In an exemplary embodiment, at least a portion of thetubular assembly comprises a microstructure comprising a hard phasestructure and a soft phase structure. In an exemplary embodiment, theportion of the tubular assembly comprises, by weight percentage, 0.065%C, 1.44% Mn, 0.01% P, 0.002% S, 0.24% Si, 0.01% Cu, 0.01% Ni, 0.02% Cr,0.05% V, 0.01% Mo, 0.01% Nb, and 0.01% Ti. In an exemplary embodiment,the portion of the tubular assembly comprises, by weight percentage,0.18% C, 1.28% Mn, 0.017% P, 0.004% S, 0.29% Si, 0.01% Cu, 0.01% Ni,0.03% Cr, 0.04% V, 0.01% Mo, 0.03% Nb, and 0.01% Ti. In an exemplaryembodiment, the portion of the tubular assembly comprises, by weightpercentage, 0.08% C, 0.82% Mn, 0.006% P, 0.003% S, 0.30% Si, 0.06% Cu,0.05% Ni, 0.05% Cr, 0.03% V, 0.03% Mo, 0.01% Nb, and 0.01% Ti. In anexemplary embodiment, the portion of the tubular assembly comprises amicrostructure comprising one or more of the following: martensite,pearlite, vanadium carbide, nickel carbide, or titanium carbide. In anexemplary embodiment, the portion of the tubular assembly comprises amicrostructure comprising one or more of the following: pearlite orpearlite striation. In an exemplary embodiment, the portion of thetubular assembly comprises a microstructure comprising one or more ofthe following: grain pearlite, widmanstatten martensite, vanadiumcarbide, nickel carbide, or titanium carbide. In an exemplaryembodiment, the portion of the tubular assembly comprises amicrostructure comprising one or more of the following: ferrite, grainpearlite, or martensite. In an exemplary embodiment, the portion of thetubular assembly comprises a microstructure comprising one or more ofthe following: ferrite, martensite, or bainite. In an exemplaryembodiment, the portion of the tubular assembly comprises amicrostructure comprising one or more of the following: bainite,pearlite, or ferrite. In an exemplary embodiment, the portion of thetubular assembly comprises a yield strength of about 67 ksi and atensile strength of about 95 ksi. In an exemplary embodiment, theportion of the tubular assembly comprises a yield strength of about 82ksi and a tensile strength of about 130 ksi. In an exemplary embodiment,the portion of the tubular assembly comprises a yield strength of about60 ksi and a tensile strength of about 97 ksi.

An expandable tubular member has been described, wherein a yield pointof the expandable tubular member after a radial expansion and plasticdeformation is at least about 5.8% greater than the yield point of theexpandable tubular member prior to the radial expansion and plasticdeformation. In an exemplary embodiment, the tubular member includes awellbore casing, a pipeline, or a structural support.

A method of determining the expandability of a selected tubular memberhas been described that includes determining an anisotropy value for theselected tubular member, determining a strain hardening value for theselected tubular member; and multiplying the anisotropy value times thestrain hardening value to generate an expandability value for theselected tubular member. In an exemplary embodiment, an anisotropy valuegreater than 0.12 indicates that the tubular member is suitable forradial expansion and plastic deformation. In an exemplary embodiment,the tubular member includes a wellbore casing, a pipeline, or astructural support.

A method of radially expanding and plastically deforming tubular membershas been described that includes selecting a tubular member; determiningan anisotropy value for the selected tubular member; determining astrain hardening value for the selected tubular member; multiplying theanisotropy value times the strain hardening value to generate anexpandability value for the selected tubular member; and if theanisotropy value is greater than 0.12, then radially expanding andplastically deforming the selected tubular member. In an exemplaryembodiment, the tubular member includes a wellbore casing, a pipeline,or a structural support. In an exemplary embodiment, radially expandingand plastically deforming the selected tubular member includes:inserting the selected tubular member into a preexisting structure; andthen radially expanding and plastically deforming the selected tubularmember. In an exemplary embodiment, the preexisting structure includes awellbore that traverses a subterranean formation.

A radially expandable multiple tubular member apparatus has beendescribed that includes a first tubular member; a second tubular memberengaged with the first tubular member forming a joint; a sleeveoverlapping and coupling the first and second tubular members at thejoint; the sleeve having opposite tapered ends and a flange engaged in arecess formed in an adjacent tubular member; and one of the tapered endsbeing a surface formed on the flange. In an exemplary embodiment, therecess includes a tapered wall in mating engagement with the tapered endformed on the flange. In an exemplary embodiment, the sleeve includes aflange at each tapered end and each tapered end is formed on arespective flange. In an exemplary embodiment, each tubular memberincludes a recess. In an exemplary embodiment, each flange is engaged ina respective one of the recesses. In an exemplary embodiment, eachrecess includes a tapered wall in mating engagement with the tapered endformed on a respective one of the flanges.

A method of joining radially expandable multiple tubular members hasalso been described that includes providing a first tubular member;engaging a second tubular member with the first tubular member to form ajoint; providing a sleeve having opposite tapered ends and a flange, oneof the tapered ends being a surface formed on the flange; and mountingthe sleeve for overlapping and coupling the first and second tubularmembers at the joint, wherein the flange is engaged in a recess formedin an adjacent one of the tubular members. In an exemplary embodiment,the method further includes providing a tapered wall in the recess formating engagement with the tapered end formed on the flange. In anexemplary embodiment, the method further includes providing a flange ateach tapered end wherein each tapered end is formed on a respectiveflange. In an exemplary embodiment, the method further includesproviding a recess in each tubular member. In an exemplary embodiment,the method further includes engaging each flange in a respective one ofthe recesses. In an exemplary embodiment, the method further includesproviding a tapered wall in each recess for mating engagement with thetapered end formed on a respective one of the flanges.

A radially expandable multiple tubular member apparatus has beendescribed that includes a first tubular member; a second tubular memberengaged with the first tubular member forming a joint; and a sleeveoverlapping and coupling the first and second tubular members at thejoint; wherein at least a portion of the sleeve is comprised of afrangible material.

A radially expandable multiple tubular member apparatus has beendescribed that includes a first tubular member; a second tubular memberengaged with the first tubular member forming a joint; and a sleeveoverlapping and coupling the first and second tubular members at thejoint; wherein the wall thickness of the sleeve is variable.

A method of joining radially expandable multiple tubular members hasbeen described that includes providing a first tubular member; engaginga second tubular member with the first tubular member to form a joint;providing a sleeve comprising a frangible material; and mounting thesleeve for overlapping and coupling the first and second tubular membersat the joint.

A method of joining radially expandable multiple tubular members hasbeen described that includes providing a first tubular member; engaginga second tubular member with the first tubular member to form a joint;providing a sleeve comprising a variable wall thickness; and mountingthe sleeve for overlapping and coupling the first and second tubularmembers at the joint.

An expandable tubular assembly has been described that includes a firsttubular member; a second tubular member coupled to the first tubularmember; and means for increasing the axial compression loading capacityof the coupling between the first and second tubular members before andafter a radial expansion and plastic deformation of the first and secondtubular members.

An expandable tubular assembly has been described that includes a firsttubular member; a second tubular member coupled to the first tubularmember; and means for increasing the axial tension loading capacity ofthe coupling between the first and second tubular members before andafter a radial expansion and plastic deformation of the first and secondtubular members.

An expandable tubular assembly has been described that includes a firsttubular member; a second tubular member coupled to the first tubularmember; and means for increasing the axial compression and tensionloading capacity of the coupling between the first and second tubularmembers before and after a radial expansion and plastic deformation ofthe first and second tubular members.

An expandable tubular assembly has been described that includes a firsttubular member; a second tubular member coupled to the first tubularmember; and means for avoiding stress risers in the coupling between thefirst and second tubular members before and after a radial expansion andplastic deformation of the first and second tubular members.

An expandable tubular assembly has been described that includes a firsttubular member; a second tubular member coupled to the first tubularmember; and means for inducing stresses at selected portions of thecoupling between the first and second tubular members before and after aradial expansion and plastic deformation of the first and second tubularmembers.

In several exemplary embodiments of the apparatus described above, thesleeve is circumferentially tensioned; and wherein the first and secondtubular members are circumferentially compressed.

In several exemplary embodiments of the method described above, themethod further includes maintaining the sleeve in circumferentialtension; and maintaining the first and second tubular members incircumferential compression before, during, and/or after the radialexpansion and plastic deformation of the first and second tubularmembers.

An expandable tubular assembly has been described that includes a firsttubular member, a second tubular member coupled to the first tubularmember, a first threaded connection for coupling a portion of the firstand second tubular members, a second threaded connection spaced apartfrom the first threaded connection for coupling another portion of thefirst and second tubular members, a tubular sleeve coupled to andreceiving end portions of the first and second tubular members, and asealing element positioned between the first and second spaced apartthreaded connections for sealing an interface between the first andsecond tubular member, wherein the sealing element is positioned withinan annulus defined between the first and second tubular members. In anexemplary embodiment, the annulus is at least partially defined by anirregular surface. In an exemplary embodiment, the annulus is at leastpartially defined by a toothed surface. In an exemplary embodiment, thesealing element comprises an elastomeric material. In an exemplaryembodiment, the sealing element comprises a metallic material. In anexemplary embodiment, the sealing element comprises an elastomeric and ametallic material.

A method of joining radially expandable multiple tubular members hasbeen described that includes providing a first tubular member, providinga second tubular member, providing a sleeve, mounting the sleeve foroverlapping and coupling the first and second tubular members,threadably coupling the first and second tubular members at a firstlocation, threadably coupling the first and second tubular members at asecond location spaced apart from the first location, and sealing aninterface between the first and second tubular members between the firstand second locations using a compressible sealing element. In anexemplary embodiment, the sealing element includes an irregular surface.In an exemplary embodiment, the sealing element includes a toothedsurface. In an exemplary embodiment, the sealing element comprises anelastomeric material. In an exemplary embodiment, the sealing elementcomprises a metallic material. In an exemplary embodiment, the sealingelement comprises an elastomeric and a metallic material.

An expandable tubular assembly has been described that includes a firsttubular member, a second tubular member coupled to the first tubularmember, a first threaded connection for coupling a portion of the firstand second tubular members, a second threaded connection spaced apartfrom the first threaded connection for coupling another portion of thefirst and second tubular members, and a plurality of spaced aparttubular sleeves coupled to and receiving end portions of the first andsecond tubular members. In an exemplary embodiment, at least one of thetubular sleeves is positioned in opposing relation to the first threadedconnection; and wherein at least one of the tubular sleeves ispositioned in opposing relation to the second threaded connection. In anexemplary embodiment, at least one of the tubular sleeves is notpositioned in opposing relation to the first and second threadedconnections.

A method of joining radially expandable multiple tubular members hasbeen described that includes providing a first tubular member, providinga second tubular member, threadably coupling the first and secondtubular members at a first location, threadably coupling the first andsecond tubular members at a second location spaced apart from the firstlocation, providing a plurality of sleeves, and mounting the sleeves atspaced apart locations for overlapping and coupling the first and secondtubular members. In an exemplary embodiment, at least one of the tubularsleeves is positioned in opposing relation to the first threadedcoupling; and wherein at least one of the tubular sleeves is positionedin opposing relation to the second threaded coupling. In an exemplaryembodiment, at least one of the tubular sleeves is not positioned inopposing relation to the first and second threaded couplings.

An expandable tubular assembly has been described that includes a firsttubular member, a second tubular member coupled to the first tubularmember, and a plurality of spaced apart tubular sleeves coupled to andreceiving end portions of the first and second tubular members.

A method of joining radially expandable multiple tubular members hasbeen described that includes providing a first tubular member, providinga second tubular member, providing a plurality of sleeves, coupling thefirst and second tubular members, and mounting the sleeves at spacedapart locations for overlapping and coupling the first and secondtubular members.

An expandable tubular assembly has been described that includes a firsttubular member, a second tubular member coupled to the first tubularmember, a threaded connection for coupling a portion of the first andsecond tubular members, and a tubular sleeves coupled to and receivingend portions of the first and second tubular members, wherein at least aportion of the threaded connection is upset. In an exemplary embodiment,at least a portion of tubular sleeve penetrates the first tubularmember.

A method of joining radially expandable multiple tubular members hasbeen described that includes providing a first tubular member, providinga second tubular member, threadably coupling the first and secondtubular members, and upsetting the threaded coupling. In an exemplaryembodiment, the first tubular member further comprises an annularextension extending therefrom, and the flange of the sleeve defines anannular recess for receiving and mating with the annular extension ofthe first tubular member. In an exemplary embodiment, the first tubularmember further comprises an annular extension extending therefrom; andthe flange of the sleeve defines an annular recess for receiving andmating with the annular extension of the first tubular member.

A radially expandable multiple tubular member apparatus has beendescribed that includes a first tubular member, a second tubular memberengaged with the first tubular member forming a joint, a sleeveoverlapping and coupling the first and second tubular members at thejoint, and one or more stress concentrators for concentrating stressesin the joint. In an exemplary embodiment, one or more of the stressconcentrators comprises one or more external grooves defined in thefirst tubular member. In an exemplary embodiment, one or more of thestress concentrators comprises one or more internal grooves defined inthe second tubular member. In an exemplary embodiment, one or more ofthe stress concentrators comprises one or more openings defined in thesleeve. In an exemplary embodiment, one or more of the stressconcentrators comprises one or more external grooves defined in thefirst tubular member; and one or more of the stress concentratorscomprises one or more internal grooves defined in the second tubularmember. In an exemplary embodiment, one or more of the stressconcentrators comprises one or more external grooves defined in thefirst tubular member; and one or more of the stress concentratorscomprises one or more openings defined in the sleeve. In an exemplaryembodiment, one or more of the stress concentrators comprises one ormore internal grooves defined in the second tubular member; and one ormore of the stress concentrators comprises one or more openings definedin the sleeve. In an exemplary embodiment, one or more of the stressconcentrators comprises one or more external grooves defined in thefirst tubular member; wherein one or more of the stress concentratorscomprises one or more internal grooves defined in the second tubularmember; and wherein one or more of the stress concentrators comprisesone or more openings defined in the sleeve.

A method of joining radially expandable multiple tubular members hasbeen described that includes providing a first tubular member, engaginga second tubular member with the first tubular member to form a joint,providing a sleeve having opposite tapered ends and a flange, one of thetapered ends being a surface formed on the flange, and concentratingstresses within the joint. In an exemplary embodiment, concentratingstresses within the joint comprises using the first tubular member toconcentrate stresses within the joint. In an exemplary embodiment,concentrating stresses within the joint comprises using the secondtubular member to concentrate stresses within the joint. In an exemplaryembodiment, concentrating stresses within the joint comprises using thesleeve to concentrate stresses within the joint. In an exemplaryembodiment, concentrating stresses within the joint comprises using thefirst tubular member and the second tubular member to concentratestresses within the joint. In an exemplary embodiment, concentratingstresses within the joint comprises using the first tubular member andthe sleeve to concentrate stresses within the joint. In an exemplaryembodiment, concentrating stresses within the joint comprises using thesecond tubular member and the sleeve to concentrate stresses within thejoint. In an exemplary embodiment, concentrating stresses within thejoint comprises using the first tubular member, the second tubularmember, and the sleeve to concentrate stresses within the joint.

A system for radially expanding and plastically deforming a firsttubular member coupled to a second tubular member by a mechanicalconnection has been described that includes means for radially expandingthe first and second tubular members, and means for maintaining portionsof the first and second tubular member in circumferential compressionfollowing the radial expansion and plastic deformation of the first andsecond tubular members.

A system for radially expanding and plastically deforming a firsttubular member coupled to a second tubular member by a mechanicalconnection has been described that includes means for radially expandingthe first and second tubular members; and means for concentratingstresses within the mechanical connection during the radial expansionand plastic deformation of the first and second tubular members.

A system for radially expanding and plastically deforming a firsttubular member coupled to a second tubular member by a mechanicalconnection has been described that includes means for radially expandingthe first and second tubular members; means for maintaining portions ofthe first and second tubular member in circumferential compressionfollowing the radial expansion and plastic deformation of the first andsecond tubular members; and means for concentrating stresses within themechanical connection during the radial expansion and plasticdeformation of the first and second tubular members.

A radially expandable tubular member apparatus has been described thatincludes a first tubular member; a second tubular member engaged withthe first tubular member forming a joint; and a sleeve overlapping andcoupling the first and second tubular members at the joint; wherein,prior to a radial expansion and plastic deformation of the apparatus, apredetermined portion of the apparatus has a lower yield point thananother portion of the apparatus. In an exemplary embodiment, the carboncontent of the predetermined portion of the apparatus is less than orequal to 0.12 percent; and wherein the carbon equivalent value for thepredetermined portion of the apparatus is less than 0.21. In anexemplary embodiment, the carbon content of the predetermined portion ofthe apparatus is greater than 0.12 percent; and wherein the carbonequivalent value for the predetermined portion of the apparatus is lessthan 0.36. In an exemplary embodiment, the apparatus further includesmeans for maintaining portions of the first and second tubular member incircumferential compression following the radial expansion and plasticdeformation of the first and second tubular members. In an exemplaryembodiment, the apparatus further includes means for concentratingstresses within the mechanical connection during the radial expansionand plastic deformation of the first and second tubular members. In anexemplary embodiment, the apparatus further includes means formaintaining portions of the first and second tubular member incircumferential compression following the radial expansion and plasticdeformation of the first and second tubular members; and means forconcentrating stresses within the mechanical connection during theradial expansion and plastic deformation of the first and second tubularmembers. In an exemplary embodiment, the apparatus further includes oneor more stress concentrators for concentrating stresses in the joint. Inan exemplary embodiment, one or more of the stress concentratorscomprises one or more external grooves defined in the first tubularmember. In an exemplary embodiment, one or more of the stressconcentrators comprises one or more internal grooves defined in thesecond tubular member. In an exemplary embodiment, one or more of thestress concentrators comprises one or more openings defined in thesleeve. In an exemplary embodiment, one or more of the stressconcentrators comprises one or more external grooves defined in thefirst tubular member; and wherein one or more of the stressconcentrators comprises one or more internal grooves defined in thesecond tubular member. In an exemplary embodiment, one or more of thestress concentrators comprises one or more external grooves defined inthe first tubular member; and wherein one or more of the stressconcentrators comprises one or more openings defined in the sleeve. Inan exemplary embodiment, one or more of the stress concentratorscomprises one or more internal grooves defined in the second tubularmember; and wherein one or more of the stress concentrators comprisesone or more openings defined in the sleeve. In an exemplary embodiment,one or more of the stress concentrators comprises one or more externalgrooves defined in the first tubular member; wherein one or more of thestress concentrators comprises one or more internal grooves defined inthe second tubular member; and wherein one or more of the stressconcentrators comprises one or more openings defined in the sleeve. Inan exemplary embodiment, the first tubular member further comprises anannular extension extending therefrom; and wherein the flange of thesleeve defines an annular recess for receiving and mating with theannular extension of the first tubular member. In an exemplaryembodiment, the apparatus further includes a threaded connection forcoupling a portion of the first and second tubular members; wherein atleast a portion of the threaded connection is upset. In an exemplaryembodiment, at least a portion of tubular sleeve penetrates the firsttubular member. In an exemplary embodiment, the apparatus furtherincludes means for increasing the axial compression loading capacity ofthe joint between the first and second tubular members before and aftera radial expansion and plastic deformation of the first and secondtubular members. In an exemplary embodiment, the apparatus furtherincludes means for increasing the axial tension loading capacity of thejoint between the first and second tubular members before and after aradial expansion and plastic deformation of the first and second tubularmembers. In an exemplary embodiment, the apparatus further includesmeans for increasing the axial compression and tension loading capacityof the joint between the first and second tubular members before andafter a radial expansion and plastic deformation of the first and secondtubular members. In an exemplary embodiment, the apparatus furtherincludes means for avoiding stress risers in the joint between the firstand second tubular members before and after a radial expansion andplastic deformation of the first and second tubular members. In anexemplary embodiment, the apparatus further includes means for inducingstresses at selected portions of the coupling between the first andsecond tubular members before and after a radial expansion and plasticdeformation of the first and second tubular members. In an exemplaryembodiment, the sleeve is circumferentially tensioned; and wherein thefirst and second tubular members are circumferentially compressed. In anexemplary embodiment, the means for increasing the axial compressionloading capacity of the coupling between the first and second tubularmembers before and after a radial expansion and plastic deformation ofthe first and second tubular members is circumferentially tensioned; andwherein the first and second tubular members are circumferentiallycompressed. In an exemplary embodiment, the means for increasing theaxial tension loading capacity of the coupling between the first andsecond tubular members before and after a radial expansion and plasticdeformation of the first and second tubular members is circumferentiallytensioned; and wherein the first and second tubular members arecircumferentially compressed. In an exemplary embodiment, the means forincreasing the axial compression and tension loading capacity of thecoupling between the first and second tubular members before and after aradial expansion and plastic deformation of the first and second tubularmembers is circumferentially tensioned; and wherein the first and secondtubular members are circumferentially compressed. In an exemplaryembodiment, the means for avoiding stress risers in the coupling betweenthe first and second tubular members before and after a radial expansionand plastic deformation of the first and second tubular members iscircumferentially tensioned; and wherein the first and second tubularmembers are circumferentially compressed. In an exemplary embodiment,the means for inducing stresses at selected portions of the couplingbetween the first and second tubular members before and after a radialexpansion and plastic deformation of the first and second tubularmembers is circumferentially tensioned; and wherein the first and secondtubular members are circumferentially compressed. In an exemplaryembodiment, at least a portion of the sleeve is comprised of a frangiblematerial. In an exemplary embodiment, the wall thickness of the sleeveis variable. In an exemplary embodiment, the predetermined portion ofthe apparatus has a higher ductility and a lower yield point prior tothe radial expansion and plastic deformation than after the radialexpansion and plastic deformation. In an exemplary embodiment, thepredetermined portion of the apparatus has a higher ductility prior tothe radial expansion and plastic deformation than after the radialexpansion and plastic deformation. In an exemplary embodiment, thepredetermined portion of the apparatus has a lower yield point prior tothe radial expansion and plastic deformation than after the radialexpansion and plastic deformation. In an exemplary embodiment, thepredetermined portion of the apparatus has a larger inside diameterafter the radial expansion and plastic deformation than other portionsof the tubular assembly. In an exemplary embodiment, the sleeve iscircumferentially tensioned; and wherein the first and second tubularmembers are circumferentially compressed. In an exemplary embodiment,the sleeve is circumferentially tensioned; and wherein the first andsecond tubular members are circumferentially compressed. In an exemplaryembodiment, the apparatus further includes positioning another apparatuswithin the preexisting structure in overlapping relation to theapparatus; and radially expanding and plastically deforming the otherapparatus within the preexisting structure; wherein, prior to the radialexpansion and plastic deformation of the apparatus, a predeterminedportion of the other apparatus has a lower yield point than anotherportion of the other apparatus. In an exemplary embodiment, the insidediameter of the radially expanded and plastically deformed other portionof the apparatus is equal to the inside diameter of the radiallyexpanded and plastically deformed other portion of the other apparatus.In an exemplary embodiment, the predetermined portion of the apparatuscomprises an end portion of the apparatus. In an exemplary embodiment,the predetermined portion of the apparatus comprises a plurality ofpredetermined portions of the apparatus. In an exemplary embodiment, thepredetermined portion of the apparatus comprises a plurality of spacedapart predetermined portions of the apparatus. In an exemplaryembodiment, the other portion of the apparatus comprises an end portionof the apparatus. In an exemplary embodiment, the other portion of theapparatus comprises a plurality of other portions of the apparatus. Inan exemplary embodiment, the other portion of the apparatus comprises aplurality of spaced apart other portions of the apparatus. In anexemplary embodiment, the apparatus comprises a plurality of tubularmembers coupled to one another by corresponding tubular couplings. In anexemplary embodiment, the tubular couplings comprise the predeterminedportions of the apparatus; and wherein the tubular members comprise theother portion of the apparatus. In an exemplary embodiment, one or moreof the tubular couplings comprise the predetermined portions of theapparatus. In an exemplary embodiment, one or more of the tubularmembers comprise the predetermined portions of the apparatus. In anexemplary embodiment, the predetermined portion of the apparatus definesone or more openings. In an exemplary embodiment, one or more of theopenings comprise slots. In an exemplary embodiment, the anisotropy forthe predetermined portion of the apparatus is greater than 1. In anexemplary embodiment, the anisotropy for the predetermined portion ofthe apparatus is greater than 1. In an exemplary embodiment, the strainhardening exponent for the predetermined portion of the apparatus isgreater than 0.12. In an exemplary embodiment, the anisotropy for thepredetermined portion of the apparatus is greater than 1; and whereinthe strain hardening exponent for the predetermined portion of theapparatus is greater than 0.12. In an exemplary embodiment, thepredetermined portion of the apparatus comprises a first steel alloycomprising: 0.065% C, 1.44% Mn, 0.01% P, 0.002% S, 0.24% Si, 0.01% Cu,0.01% Ni, and 0.02% Cr. In an exemplary embodiment, the yield point ofthe predetermined portion of the apparatus is at most about 46.9 ksiprior to the radial expansion and plastic deformation; and wherein theyield point of the predetermined portion of the apparatus is at leastabout 65.9 ksi after the radial expansion and plastic deformation. In anexemplary embodiment, the yield point of the predetermined portion ofthe apparatus after the radial expansion and plastic deformation is atleast about 40% greater than the yield point of the predeterminedportion of the apparatus prior to the radial expansion and plasticdeformation. In an exemplary embodiment, the anisotropy of thepredetermined portion of the apparatus, prior to the radial expansionand plastic deformation, is about 1.48. In an exemplary embodiment, thepredetermined portion of the apparatus comprises a second steel alloycomprising: 0.18% C, 1.28% Mn, 0.017% P, 0.004% S, 0.29% Si, 0.01% Cu,0.01% Ni, and 0.03% Cr. In an exemplary embodiment, the yield point ofthe predetermined portion of the apparatus is at most about 57.8 ksiprior to the radial expansion and plastic deformation; and wherein theyield point of the predetermined portion of the apparatus is at leastabout 74.4 ksi after the radial expansion and plastic deformation. In anexemplary embodiment, the yield point of the predetermined portion ofthe apparatus after the radial expansion and plastic deformation is atleast about 28% greater than the yield point of the predeterminedportion of the apparatus prior to the radial expansion and plasticdeformation. In an exemplary embodiment, the anisotropy of thepredetermined portion of the apparatus, prior to the radial expansionand plastic deformation, is about 1.04. In an exemplary embodiment, thepredetermined portion of the apparatus comprises a third steel alloycomprising: 0.08% C, 0.82% Mn, 0.006% P, 0.003% S, 0.30% Si, 0.16% Cu,0.05% Ni, and 0.05% Cr. In an exemplary embodiment, the anisotropy ofthe predetermined portion of the apparatus, prior to the radialexpansion and plastic deformation, is about 1.92. In an exemplaryembodiment, the predetermined portion of the apparatus comprises afourth steel alloy comprising: 0.02% C, 1.31% Mn, 0.02% P, 0.001% S,0.45% Si, 9.1% Ni, and 18.7% Cr. In an exemplary embodiment, theanisotropy of the predetermined portion of the apparatus, prior to theradial expansion and plastic deformation, is about 1.34. In an exemplaryembodiment, the yield point of the predetermined portion of theapparatus is at most about 46.9 ksi prior to the radial expansion andplastic deformation; and wherein the yield point of the predeterminedportion of the apparatus is at least about 65.9 ksi after the radialexpansion and plastic deformation. In an exemplary embodiment, the yieldpoint of the predetermined portion of the apparatus after the radialexpansion and plastic deformation is at least about 40% greater than theyield point of the predetermined portion of the apparatus prior to theradial expansion and plastic deformation. In an exemplary embodiment,the anisotropy of the predetermined portion of the apparatus, prior tothe radial expansion and plastic deformation, is at least about 1.48. Inan exemplary embodiment, the yield point of the predetermined portion ofthe apparatus is at most about 57.8 ksi prior to the radial expansionand plastic deformation; and wherein the yield point of thepredetermined portion of the apparatus is at least about 74.4 ksi afterthe radial expansion and plastic deformation. In an exemplaryembodiment, the yield point of the predetermined portion of theapparatus after the radial expansion and plastic deformation is at leastabout 28% greater than the yield point of the predetermined portion ofthe apparatus prior to the radial expansion and plastic deformation. Inan exemplary embodiment, the anisotropy of the predetermined portion ofthe apparatus, prior to the radial expansion and plastic deformation, isat least about 1.04. In an exemplary embodiment, the anisotropy of thepredetermined portion of the apparatus, prior to the radial expansionand plastic deformation, is at least about 1.92. In an exemplaryembodiment, the anisotropy of the predetermined portion of theapparatus, prior to the radial expansion and plastic deformation, is atleast about 1.34. In an exemplary embodiment, the anisotropy of thepredetermined portion of the apparatus, prior to the radial expansionand plastic deformation, ranges from about 1.04 to about 1.92. In anexemplary embodiment, the yield point of the predetermined portion ofthe apparatus, prior to the radial expansion and plastic deformation,ranges from about 47.6 ksi to about 61.7 ksi. In an exemplaryembodiment, the expandability coefficient of the predetermined portionof the apparatus, prior to the radial expansion and plastic deformation,is greater than 0.12. In an exemplary embodiment, the expandabilitycoefficient of the predetermined portion of the apparatus is greaterthan the expandability coefficient of the other portion of theapparatus. In an exemplary embodiment, the apparatus comprises awellbore casing. In an exemplary embodiment, the apparatus comprises apipeline. In an exemplary embodiment, the apparatus comprises astructural support.

A radially expandable tubular member apparatus has been described thatincludes a first tubular member; a second tubular member engaged withthe first tubular member forming a joint; a sleeve overlapping andcoupling the first and second tubular members at the joint; the sleevehaving opposite tapered ends and a flange engaged in a recess formed inan adjacent tubular member; and one of the tapered ends being a surfaceformed on the flange; wherein, prior to a radial expansion and plasticdeformation of the apparatus, a predetermined portion of the apparatushas a lower yield point than another portion of the apparatus. In anexemplary embodiment, the recess includes a tapered wall in matingengagement with the tapered end formed on the flange. In an exemplaryembodiment, the sleeve includes a flange at each tapered end and eachtapered end is formed on a respective flange. In an exemplaryembodiment, each tubular member includes a recess. In an exemplaryembodiment, each flange is engaged in a respective one of the recesses.In an exemplary embodiment, each recess includes a tapered wall inmating engagement with the tapered end formed on a respective one of theflanges. In an exemplary embodiment, the predetermined portion of theapparatus has a higher ductility and a lower yield point prior to theradial expansion and plastic deformation than after the radial expansionand plastic deformation. In an exemplary embodiment, the predeterminedportion of the apparatus has a higher ductility prior to the radialexpansion and plastic deformation than after the radial expansion andplastic deformation. In an exemplary embodiment, the predeterminedportion of the apparatus has a lower yield point prior to the radialexpansion and plastic deformation than after the radial expansion andplastic deformation. In an exemplary embodiment, the predeterminedportion of the apparatus has a larger inside diameter after the radialexpansion and plastic deformation than other portions of the tubularassembly. In an exemplary embodiment, the apparatus further includespositioning another apparatus within the preexisting structure inoverlapping relation to the apparatus; and radially expanding andplastically deforming the other apparatus within the preexistingstructure; wherein, prior to the radial expansion and plasticdeformation of the apparatus, a predetermined portion of the otherapparatus has a lower yield point than another portion of the otherapparatus. In an exemplary embodiment, the inside diameter of theradially expanded and plastically deformed other portion of theapparatus is equal to the inside diameter of the radially expanded andplastically deformed other portion of the other apparatus. In anexemplary embodiment, the predetermined portion of the apparatuscomprises an end portion of the apparatus. In an exemplary embodiment,the predetermined portion of the apparatus comprises a plurality ofpredetermined portions of the apparatus. In an exemplary embodiment, thepredetermined portion of the apparatus comprises a plurality of spacedapart predetermined portions of the apparatus. In an exemplaryembodiment, the other portion of the apparatus comprises an end portionof the apparatus. In an exemplary embodiment, the other portion of theapparatus comprises a plurality of other portions of the apparatus. Inan exemplary embodiment, the other portion of the apparatus comprises aplurality of spaced apart other portions of the apparatus. In anexemplary embodiment, the apparatus comprises a plurality of tubularmembers coupled to one another by corresponding tubular couplings. In anexemplary embodiment, the tubular couplings comprise the predeterminedportions of the apparatus; and wherein the tubular members comprise theother portion of the apparatus. In an exemplary embodiment, one or moreof the tubular couplings comprise the predetermined portions of theapparatus. In an exemplary embodiment, one or more of the tubularmembers comprise the predetermined portions of the apparatus. In anexemplary embodiment, the predetermined portion of the apparatus definesone or more openings. In an exemplary embodiment, one or more of theopenings comprise slots. In an exemplary embodiment, the anisotropy forthe predetermined portion of the apparatus is greater than 1. In anexemplary embodiment, the anisotropy for the predetermined portion ofthe apparatus is greater than 1. In an exemplary embodiment, the strainhardening exponent for the predetermined portion of the apparatus isgreater than 0.12. In an exemplary embodiment, the anisotropy for thepredetermined portion of the apparatus is greater than 1; and whereinthe strain hardening exponent for the predetermined portion of theapparatus is greater than 0.12. In an exemplary embodiment, thepredetermined portion of the apparatus comprises a first steel alloycomprising: 0.065% C, 1.44% Mn, 0.01% P, 0.002% S, 0.24% Si, 0.01% Cu,0.01% Ni, and 0.02% Cr. In an exemplary embodiment, the yield point ofthe predetermined portion of the apparatus is at most about 46.9 ksiprior to the radial expansion and plastic deformation; and wherein theyield point of the predetermined portion of the apparatus is at leastabout 65.9 ksi after the radial expansion and plastic deformation. In anexemplary embodiment, the yield point of the predetermined portion ofthe apparatus after the radial expansion and plastic deformation is atleast about 40% greater than the yield point of the predeterminedportion of the apparatus prior to the radial expansion and plasticdeformation. In an exemplary embodiment, the anisotropy of thepredetermined portion of the apparatus, prior to the radial expansionand plastic deformation, is about 1.48. In an exemplary embodiment, thepredetermined portion of the apparatus comprises a second steel alloycomprising: 0.18% C, 1.28% Mn, 0.017% P, 0.004% S, 0.29% Si, 0.01% Cu,0.01% Ni, and 0.03% Cr. In an exemplary embodiment, the yield point ofthe predetermined portion of the apparatus is at most about 57.8 ksiprior to the radial expansion and plastic deformation; and wherein theyield point of the predetermined portion of the apparatus is at leastabout 74.4 ksi after the radial expansion and plastic deformation. In anexemplary embodiment, the yield point of the predetermined portion ofthe apparatus after the radial expansion and plastic deformation is atleast about 28% greater than the yield point of the predeterminedportion of the apparatus prior to the radial expansion and plasticdeformation. In an exemplary embodiment, the anisotropy of thepredetermined portion of the apparatus, prior to the radial expansionand plastic deformation, is about 1.04. In an exemplary embodiment, thepredetermined portion of the apparatus comprises a third steel alloycomprising: 0.08% C, 0.82% Mn, 0.006% P, 0.003% S, 0.30% Si, 0.16% Cu,0.05% Ni, and 0.05% Cr. In an exemplary embodiment, the anisotropy ofthe predetermined portion of the apparatus, prior to the radialexpansion and plastic deformation, is about 1.92. In an exemplaryembodiment, the predetermined portion of the apparatus comprises afourth steel alloy comprising: 0.02% C, 1.31% Mn, 0.02% P, 0.001% S,0.45% Si, 9.1% Ni, and 18.7% Cr. In an exemplary embodiment, theanisotropy of the predetermined portion of the apparatus, prior to theradial expansion and plastic deformation, is about 1.34. In an exemplaryembodiment, the yield point of the predetermined portion of theapparatus is at most about 46.9 ksi prior to the radial expansion andplastic deformation; and wherein the yield point of the predeterminedportion of the apparatus is at least about 65.9 ksi after the radialexpansion and plastic deformation. In an exemplary embodiment, the yieldpoint of the predetermined portion of the apparatus after the radialexpansion and plastic deformation is at least about 40% greater than theyield point of the predetermined portion of the apparatus prior to theradial expansion and plastic deformation. In an exemplary embodiment,the anisotropy of the predetermined portion of the apparatus, prior tothe radial expansion and plastic deformation, is at least about 1.48. Inan exemplary embodiment, the yield point of the predetermined portion ofthe apparatus is at most about 57.8 ksi prior to the radial expansionand plastic deformation; and wherein the yield point of thepredetermined portion of the apparatus is at least about 74.4 ksi afterthe radial expansion and plastic deformation. In an exemplaryembodiment, the yield point of the predetermined portion of theapparatus after the radial expansion and plastic deformation is at leastabout 28% greater than the yield point of the predetermined portion ofthe apparatus prior to the radial expansion and plastic deformation. Inan exemplary embodiment, the anisotropy of the predetermined portion ofthe apparatus, prior to the radial expansion and plastic deformation, isat least about 1.04. In an exemplary embodiment, the anisotropy of thepredetermined portion of the apparatus, prior to the radial expansionand plastic deformation, is at least about 1.92. In an exemplaryembodiment, the anisotropy of the predetermined portion of theapparatus, prior to the radial expansion and plastic deformation, is atleast about 1.34. In an exemplary embodiment, the anisotropy of thepredetermined portion of the apparatus, prior to the radial expansionand plastic deformation, ranges from about 1.04 to about 1.92. In anexemplary embodiment, the yield point of the predetermined portion ofthe apparatus, prior to the radial expansion and plastic deformation,ranges from about 47.6 ksi to about 61.7 ksi. In an exemplaryembodiment, the expandability coefficient of the predetermined portionof the apparatus, prior to the radial expansion and plastic deformation,is greater than 0.12. In an exemplary embodiment, the expandabilitycoefficient of the predetermined portion of the apparatus is greaterthan the expandability coefficient of the other portion of theapparatus. In an exemplary embodiment, the apparatus comprises awellbore casing. In an exemplary embodiment, the apparatus comprises apipeline. In an exemplary embodiment, the apparatus comprises astructural support.

A method of joining radially expandable tubular members has beenprovided that includes: providing a first tubular member; engaging asecond tubular member with the first tubular member to form a joint;providing a sleeve; mounting the sleeve for overlapping and coupling thefirst and second tubular members at the joint; wherein the first tubularmember, the second tubular member, and the sleeve define a tubularassembly; and radially expanding and plastically deforming the tubularassembly; wherein, prior to the radial expansion and plasticdeformation, a predetermined portion of the tubular assembly has a loweryield point than another portion of the tubular assembly. In anexemplary embodiment, the carbon content of the predetermined portion ofthe tubular assembly is less than or equal to 0.12 percent; and whereinthe carbon equivalent value for the predetermined portion of the tubularassembly is less than 0.21. In an exemplary embodiment, the carboncontent of the predetermined portion of the tubular assembly is greaterthan 0.12 percent; and wherein the carbon equivalent value for thepredetermined portion of the tubular assembly is less than 0.36. In anexemplary embodiment, the method further includes: maintaining portionsof the first and second tubular member in circumferential compressionfollowing a radial expansion and plastic deformation of the first andsecond tubular members. In an exemplary embodiment, the method furtherincludes: concentrating stresses within the joint during a radialexpansion and plastic deformation of the first and second tubularmembers. In an exemplary embodiment, the method further includes:maintaining portions of the first and second tubular member incircumferential compression following a radial expansion and plasticdeformation of the first and second tubular members; and concentratingstresses within the joint during a radial expansion and plasticdeformation of the first and second tubular members. In an exemplaryembodiment, the method further includes: concentrating stresses withinthe joint. In an exemplary embodiment, concentrating stresses within thejoint comprises using the first tubular member to concentrate stresseswithin the joint. In an exemplary embodiment, concentrating stresseswithin the joint comprises using the second tubular member toconcentrate stresses within the joint. In an exemplary embodiment,concentrating stresses within the joint comprises using the sleeve toconcentrate stresses within the joint. In an exemplary embodiment,concentrating stresses within the joint comprises using the firsttubular member and the second tubular member to concentrate stresseswithin the joint. In an exemplary embodiment, concentrating stresseswithin the joint comprises using the first tubular member and the sleeveto concentrate stresses within the joint. In an exemplary embodiment,concentrating stresses within the joint comprises using the secondtubular member and the sleeve to concentrate stresses within the joint.In an exemplary embodiment, concentrating stresses within the jointcomprises using the first tubular member, the second tubular member, andthe sleeve to concentrate stresses within the joint. In an exemplaryembodiment, at least a portion of the sleeve is comprised of a frangiblematerial. In an exemplary embodiment, the sleeve comprises a variablewall thickness. In an exemplary embodiment, the method further includesmaintaining the sleeve in circumferential tension; and maintaining thefirst and second tubular members in circumferential compression. In anexemplary embodiment, the method further includes maintaining the sleevein circumferential tension; and maintaining the first and second tubularmembers in circumferential compression. In an exemplary embodiment, themethod further includes: maintaining the sleeve in circumferentialtension; and maintaining the first and second tubular members incircumferential compression. In an exemplary embodiment, the methodfurther includes: threadably coupling the first and second tubularmembers at a first location; threadably coupling the first and secondtubular members at a second location spaced apart from the firstlocation; providing a plurality of sleeves; and mounting the sleeves atspaced apart locations for overlapping and coupling the first and secondtubular members. In an exemplary embodiment, at least one of the tubularsleeves is positioned in opposing relation to the first threadedcoupling; and wherein at least one of the tubular sleeves is positionedin opposing relation to the second threaded coupling. In an exemplaryembodiment, at least one of the tubular sleeves is not positioned inopposing relation to the first and second threaded couplings. In anexemplary embodiment, the method further includes: threadably couplingthe first and second tubular members; and upsetting the threadedcoupling. In an exemplary embodiment, the first tubular member furthercomprises an annular extension extending therefrom; and wherein theflange of the sleeve defines an annular recess for receiving and matingwith the annular extension of the first tubular member. In an exemplaryembodiment, the predetermined portion of the tubular assembly has ahigher ductility and a lower yield point prior to the radial expansionand plastic deformation than after the radial expansion and plasticdeformation. In an exemplary embodiment, the predetermined portion ofthe tubular assembly has a higher ductility prior to the radialexpansion and plastic deformation than after the radial expansion andplastic deformation. In an exemplary embodiment, the predeterminedportion of the tubular assembly has a lower yield point prior to theradial expansion and plastic deformation than after the radial expansionand plastic deformation. In an exemplary embodiment, the predeterminedportion of the tubular assembly has a larger inside diameter after theradial expansion and plastic deformation than the other portion of thetubular assembly. In an exemplary embodiment, the method furtherincludes: positioning another tubular assembly within the preexistingstructure in overlapping relation to the tubular assembly; and radiallyexpanding and plastically deforming the other tubular assembly withinthe preexisting structure; wherein, prior to the radial expansion andplastic deformation of the tubular assembly, a predetermined portion ofthe other tubular assembly has a lower yield point than another portionof the other tubular assembly. In an exemplary embodiment, the insidediameter of the radially expanded and plastically deformed other portionof the tubular assembly is equal to the inside diameter of the radiallyexpanded and plastically deformed other portion of the other tubularassembly. In an exemplary embodiment, the predetermined portion of thetubular assembly comprises an end portion of the tubular assembly. In anexemplary embodiment, the predetermined portion of the tubular assemblycomprises a plurality of predetermined portions of the tubular assembly.In an exemplary embodiment, the predetermined portion of the tubularassembly comprises a plurality of spaced apart predetermined portions ofthe tubular assembly. In an exemplary embodiment, the other portion ofthe tubular assembly comprises an end portion of the tubular assembly.In an exemplary embodiment, the other portion of the tubular assemblycomprises a plurality of other portions of the tubular assembly. In anexemplary embodiment, the other portion of the tubular assemblycomprises a plurality of spaced apart other portions of the tubularassembly. In an exemplary embodiment, the tubular assembly comprises aplurality of tubular members coupled to one another by correspondingtubular couplings. In an exemplary embodiment, the tubular couplingscomprise the predetermined portions of the tubular assembly; and whereinthe tubular members comprise the other portion of the tubular assembly.In an exemplary embodiment, one or more of the tubular couplingscomprise the predetermined portions of the tubular assembly. In anexemplary embodiment, one or more of the tubular members comprise thepredetermined portions of the tubular assembly. In an exemplaryembodiment, the predetermined portion of the tubular assembly definesone or more openings. In an exemplary embodiment, one or more of theopenings comprise slots. In an exemplary embodiment, the anisotropy forthe predetermined portion of the tubular assembly is greater than 1. Inan exemplary embodiment, the anisotropy for the predetermined portion ofthe tubular assembly is greater than 1. In an exemplary embodiment, thestrain hardening exponent for the predetermined portion of the tubularassembly is greater than 0.12. In an exemplary embodiment, theanisotropy for the predetermined portion of the tubular assembly isgreater than 1; and wherein the strain hardening exponent for thepredetermined portion of the tubular assembly is greater than 0.12. Inan exemplary embodiment, the predetermined portion of the tubularassembly comprises a first steel alloy comprising: 0.065% C, 1.44% Mn,0.01% P, 0.002% S, 0.24% Si, 0.01% Cu, 0.01% Ni, and 0.02% Cr. In anexemplary embodiment, the yield point of the predetermined portion ofthe tubular assembly is at most about 46.9 ksi prior to the radialexpansion and plastic deformation; and wherein the yield point of thepredetermined portion of the tubular assembly is at least about 65.9 ksiafter the radial expansion and plastic deformation. In an exemplaryembodiment, the yield point of the predetermined portion of the tubularassembly after the radial expansion and plastic deformation is at leastabout 40% greater than the yield point of the predetermined portion ofthe tubular assembly prior to the radial expansion and plasticdeformation. In an exemplary embodiment, the anisotropy of thepredetermined portion of the tubular assembly, prior to the radialexpansion and plastic deformation, is about 1.48. In an exemplaryembodiment, the predetermined portion of the tubular assembly comprisesa second steel alloy comprising: 0.18% C, 1.28% Mn, 0.017% P, 0.004% S,0.29% Si, 0.01% Cu, 0.01% Ni, and 0.03% Cr. In an exemplary embodiment,the yield point of the predetermined portion of the tubular assembly isat most about 57.8 ksi prior to the radial expansion and plasticdeformation; and wherein the yield point of the predetermined portion ofthe tubular assembly is at least about 74.4 ksi after the radialexpansion and plastic deformation. In an exemplary embodiment, the yieldpoint of the predetermined portion of the tubular assembly after theradial expansion and plastic deformation is at least about 28% greaterthan the yield point of the predetermined portion of the tubularassembly prior to the radial expansion and plastic deformation. In anexemplary embodiment, the anisotropy of the predetermined portion of thetubular assembly, prior to the radial expansion and plastic deformation,is about 1.04. In an exemplary embodiment, the predetermined portion ofthe tubular assembly comprises a third steel alloy comprising: 0.08% C,0.82% Mn, 0.006% P, 0.003% S, 0.30% Si, 0.16% Cu, 0.05% Ni, and 0.05%Cr. In an exemplary embodiment, the anisotropy of the predeterminedportion of the tubular assembly, prior to the radial expansion andplastic deformation, is about 1.92. In an exemplary embodiment, thepredetermined portion of the tubular assembly comprises a fourth steelalloy comprising: 0.02% C, 1.31% Mn, 0.02% P, 0.001% S, 0.45% Si, 9.1%Ni, and 18.7% Cr. In an exemplary embodiment, the anisotropy of thepredetermined portion of the tubular assembly, prior to the radialexpansion and plastic deformation, is about 1.34. In an exemplaryembodiment, the yield point of the predetermined portion of the tubularassembly is at most about 46.9 ksi prior to the radial expansion andplastic deformation; and wherein the yield point of the predeterminedportion of the tubular assembly is at least about 65.9 ksi after theradial expansion and plastic deformation. In an exemplary embodiment,the yield point of the predetermined portion of the tubular assemblyafter the radial expansion and plastic deformation is at least about 40%greater than the yield point of the predetermined portion of the tubularassembly prior to the radial expansion and plastic deformation. In anexemplary embodiment, the anisotropy of the predetermined portion of thetubular assembly, prior to the radial expansion and plastic deformation,is at least about 1.48. In an exemplary embodiment, the yield point ofthe predetermined portion of the tubular assembly is at most about 57.8ksi prior to the radial expansion and plastic deformation; and whereinthe yield point of the predetermined portion of the tubular assembly isat least about 74.4 ksi after the radial expansion and plasticdeformation. In an exemplary embodiment, the yield point of thepredetermined portion of the tubular assembly after the radial expansionand plastic deformation is at least about 28% greater than the yieldpoint of the predetermined portion of the tubular assembly prior to theradial expansion and plastic deformation. In an exemplary embodiment,the anisotropy of the predetermined portion of the tubular assembly,prior to the radial expansion and plastic deformation, is at least about1.04. In an exemplary embodiment, the anisotropy of the predeterminedportion of the tubular assembly, prior to the radial expansion andplastic deformation, is at least about 1.92. In an exemplary embodiment,the anisotropy of the predetermined portion of the tubular assembly,prior to the radial expansion and plastic deformation, is at least about1.34. In an exemplary embodiment, the anisotropy of the predeterminedportion of the tubular assembly, prior to the radial expansion andplastic deformation, ranges from about 1.04 to about 1.92. In anexemplary embodiment, the yield point of the predetermined portion ofthe tubular assembly, prior to the radial expansion and plasticdeformation, ranges from about 47.6 ksi to about 61.7 ksi. In anexemplary embodiment, the expandability coefficient of the predeterminedportion of the tubular assembly, prior to the radial expansion andplastic deformation, is greater than 0.12. In an exemplary embodiment,the expandability coefficient of the predetermined portion of thetubular assembly is greater than the expandability coefficient of theother portion of the tubular assembly. In an exemplary embodiment, thetubular assembly comprises a wellbore casing. In an exemplaryembodiment, the tubular assembly comprises a pipeline. In an exemplaryembodiment, the tubular assembly comprises a structural support.

A method of joining radially expandable tubular members has beendescribed that includes: providing a first tubular member; engaging asecond tubular member with the first tubular member to form a joint;providing a sleeve having opposite tapered ends and a flange, one of thetapered ends being a surface formed on the flange; mounting the sleevefor overlapping and coupling the first and second tubular members at thejoint, wherein the flange is engaged in a recess formed in an adjacentone of the tubular members;

wherein the first tubular member, the second tubular member, and thesleeve define a tubular assembly; and radially expanding and plasticallydeforming the tubular assembly; wherein, prior to the radial expansionand plastic deformation, a predetermined portion of the tubular assemblyhas a lower yield point than another portion of the tubular assembly. Inan exemplary embodiment, the method further includes: providing atapered wall in the recess for mating engagement with the tapered endformed on the flange. In an exemplary embodiment, the method furtherincludes: providing a flange at each tapered end wherein each taperedend is formed on a respective flange. In an exemplary embodiment, themethod further includes: providing a recess in each tubular member. Inan exemplary embodiment, the method further includes: engaging eachflange in a respective one of the recesses. In an exemplary embodiment,the method further includes: providing a tapered wall in each recess formating engagement with the tapered end formed on a respective one of theflanges. In an exemplary embodiment, the predetermined portion of thetubular assembly has a higher ductility and a lower yield point prior tothe radial expansion and plastic deformation than after the radialexpansion and plastic deformation. In an exemplary embodiment, thepredetermined portion of the tubular assembly has a higher ductilityprior to the radial expansion and plastic deformation than after theradial expansion and plastic deformation. In an exemplary embodiment,the predetermined portion of the tubular assembly has a lower yieldpoint prior to the radial expansion and plastic deformation than afterthe radial expansion and plastic deformation. In an exemplaryembodiment, the predetermined portion of the tubular assembly has alarger inside diameter after the radial expansion and plasticdeformation than the other portion of the tubular assembly. In anexemplary embodiment, the method further includes: positioning anothertubular assembly within the preexisting structure in overlappingrelation to the tubular assembly; and radially expanding and plasticallydeforming the other tubular assembly within the preexisting structure;wherein, prior to the radial expansion and plastic deformation of thetubular assembly, a predetermined portion of the other tubular assemblyhas a lower yield point than another portion of the other tubularassembly. In an exemplary embodiment, the inside diameter of theradially expanded and plastically deformed other portion of the tubularassembly is equal to the inside diameter of the radially expanded andplastically deformed other portion of the other tubular assembly. In anexemplary embodiment, the predetermined portion of the tubular assemblycomprises an end portion of the tubular assembly. In an exemplaryembodiment, the predetermined portion of the tubular assembly comprisesa plurality of predetermined portions of the tubular assembly. In anexemplary embodiment, the predetermined portion of the tubular assemblycomprises a plurality of spaced apart predetermined portions of thetubular assembly. In an exemplary embodiment, the other portion of thetubular assembly comprises an end portion of the tubular assembly. In anexemplary embodiment, the other portion of the tubular assemblycomprises a plurality of other portions of the tubular assembly. In anexemplary embodiment, the other portion of the tubular assemblycomprises a plurality of spaced apart other portions of the tubularassembly. In an exemplary embodiment, the tubular assembly comprises aplurality of tubular members coupled to one another by correspondingtubular couplings. In an exemplary embodiment, the tubular couplingscomprise the predetermined portions of the tubular assembly; and whereinthe tubular members comprise the other portion of the tubular assembly.In an exemplary embodiment, one or more of the tubular couplingscomprise the predetermined portions of the tubular assembly. In anexemplary embodiment, one or more of the tubular members comprise thepredetermined portions of the tubular assembly. In an exemplaryembodiment, the predetermined portion of the tubular assembly definesone or more openings. In an exemplary embodiment, one or more of theopenings comprise slots. In an exemplary embodiment, the anisotropy forthe predetermined portion of the tubular assembly is greater than 1. Inan exemplary embodiment, the anisotropy for the predetermined portion ofthe tubular assembly is greater than 1. In an exemplary embodiment, thestrain hardening exponent for the predetermined portion of the tubularassembly is greater than 0.12. In an exemplary embodiment, theanisotropy for the predetermined portion of the tubular assembly isgreater than 1; and wherein the strain hardening exponent for thepredetermined portion of the tubular assembly is greater than 0.12. Inan exemplary embodiment, the predetermined portion of the tubularassembly comprises a first steel alloy comprising: 0.065% C, 1.44% Mn,0.01% P, 0.002% S, 0.24% Si, 0.01% Cu, 0.01% Ni, and 0.02% Cr. In anexemplary embodiment, the yield point of the predetermined portion ofthe tubular assembly is at most about 46.9 ksi prior to the radialexpansion and plastic deformation; and wherein the yield point of thepredetermined portion of the tubular assembly is at least about 65.9 ksiafter the radial expansion and plastic deformation. In an exemplaryembodiment, the yield point of the predetermined portion of the tubularassembly after the radial expansion and plastic deformation is at leastabout 40% greater than the yield point of the predetermined portion ofthe tubular assembly prior to the radial expansion and plasticdeformation. In an exemplary embodiment, the anisotropy of thepredetermined portion of the tubular assembly, prior to the radialexpansion and plastic deformation, is about 1.48. In an exemplaryembodiment, the predetermined portion of the tubular assembly comprisesa second steel alloy comprising: 0.18% C, 1.28% Mn, 0.017% P, 0.004% S,0.29% Si, 0.01% Cu, 0.01% Ni, and 0.03% Cr. In an exemplary embodiment,the yield point of the predetermined portion of the tubular assembly isat most about 57.8 ksi prior to the radial expansion and plasticdeformation; and wherein the yield point of the predetermined portion ofthe tubular assembly is at least about 74.4 ksi after the radialexpansion and plastic deformation. In an exemplary embodiment, the yieldpoint of the predetermined portion of the tubular assembly after theradial expansion and plastic deformation is at least about 28% greaterthan the yield point of the predetermined portion of the tubularassembly prior to the radial expansion and plastic deformation. In anexemplary embodiment, the anisotropy of the predetermined portion of thetubular assembly, prior to the radial expansion and plastic deformation,is about 1.04. In an exemplary embodiment, the predetermined portion ofthe tubular assembly comprises a third steel alloy comprising: 0.08% C,0.82% Mn, 0.006% P, 0.003% S, 0.30% Si, 0.16% Cu, 0.05% Ni, and 0.05%Cr. In an exemplary embodiment, the anisotropy of the predeterminedportion of the tubular assembly, prior to the radial expansion andplastic deformation, is about 1.92. In an exemplary embodiment, thepredetermined portion of the tubular assembly comprises a fourth steelalloy comprising: 0.02% C, 1.31% Mn, 0.02% P, 0.001% S, 0.45% Si, 9.1%Ni, and 18.7% Cr. In an exemplary embodiment, the anisotropy of thepredetermined portion of the tubular assembly, prior to the radialexpansion and plastic deformation, is about 1.34. In an exemplaryembodiment, the yield point of the predetermined portion of the tubularassembly is at most about 46.9 ksi prior to the radial expansion andplastic deformation; and wherein the yield point of the predeterminedportion of the tubular assembly is at least about 65.9 ksi after theradial expansion and plastic deformation. In an exemplary embodiment,the yield point of the predetermined portion of the tubular assemblyafter the radial expansion and plastic deformation is at least about 40%greater than the yield point of the predetermined portion of the tubularassembly prior to the radial expansion and plastic deformation. In anexemplary embodiment, the anisotropy of the predetermined portion of thetubular assembly, prior to the radial expansion and plastic deformation,is at least about 1.48. In an exemplary embodiment, the yield point ofthe predetermined portion of the tubular assembly is at most about 57.8ksi prior to the radial expansion and plastic deformation; and whereinthe yield point of the predetermined portion of the tubular assembly isat least about 74.4 ksi after the radial expansion and plasticdeformation. In an exemplary embodiment, the yield point of thepredetermined portion of the tubular assembly after the radial expansionand plastic deformation is at least about 28% greater than the yieldpoint of the predetermined portion of the tubular assembly prior to theradial expansion and plastic deformation. In an exemplary embodiment,the anisotropy of the predetermined portion of the tubular assembly,prior to the radial expansion and plastic deformation, is at least about1.04. In an exemplary embodiment, the anisotropy of the predeterminedportion of the tubular assembly, prior to the radial expansion andplastic deformation, is at least about 1.92. In an exemplary embodiment,the anisotropy of the predetermined portion of the tubular assembly,prior to the radial expansion and plastic deformation, is at least about1.34. In an exemplary embodiment, the anisotropy of the predeterminedportion of the tubular assembly, prior to the radial expansion andplastic deformation, ranges from about 1.04 to about 1.92. In anexemplary embodiment, the yield point of the predetermined portion ofthe tubular assembly, prior to the radial expansion and plasticdeformation, ranges from about 47.6 ksi to about 61.7 ksi. In anexemplary embodiment, the expandability coefficient of the predeterminedportion of the tubular assembly, prior to the radial expansion andplastic deformation, is greater than 0.12. In an exemplary embodiment,the expandability coefficient of the predetermined portion of thetubular assembly is greater than the expandability coefficient of theother portion of the tubular assembly. In an exemplary embodiment, thetubular assembly comprises a wellbore casing. In an exemplaryembodiment, the tubular assembly comprises a pipeline. In an exemplaryembodiment, the tubular assembly comprises a structural support.

An expandable tubular assembly has been described that includes a firsttubular member; a second tubular member coupled to the first tubularmember; a first threaded connection for coupling a portion of the firstand second tubular members; a second threaded connection spaced apartfrom the first threaded connection for coupling another portion of thefirst and second tubular members; a tubular sleeve coupled to andreceiving end portions of the first and second tubular members; and asealing element positioned between the first and second spaced apartthreaded connections for sealing an interface between the first andsecond tubular member; wherein the sealing element is positioned withinan annulus defined between the first and second tubular members; andwherein, prior to a radial expansion and plastic deformation of theassembly, a predetermined portion of the assembly has a lower yieldpoint than another portion of the apparatus. In an exemplary embodiment,the predetermined portion of the assembly has a higher ductility and alower yield point prior to the radial expansion and plastic deformationthan after the radial expansion and plastic deformation. In an exemplaryembodiment, the predetermined portion of the assembly has a higherductility prior to the radial expansion and plastic deformation thanafter the radial expansion and plastic deformation. In an exemplaryembodiment, the predetermined portion of the assembly has a lower yieldpoint prior to the radial expansion and plastic deformation than afterthe radial expansion and plastic deformation. In an exemplaryembodiment, the predetermined portion of the assembly has a largerinside diameter after the radial expansion and plastic deformation thanother portions of the tubular assembly. In an exemplary embodiment, theassembly further includes: positioning another assembly within thepreexisting structure in overlapping relation to the assembly; andradially expanding and plastically deforming the other assembly withinthe preexisting structure; wherein, prior to the radial expansion andplastic deformation of the assembly, a predetermined portion of theother assembly has a lower yield point than another portion of the otherassembly. In an exemplary embodiment, the inside diameter of theradially expanded and plastically deformed other portion of the assemblyis equal to the inside diameter of the radially expanded and plasticallydeformed other portion of the other assembly. In an exemplaryembodiment, the predetermined portion of the assembly comprises an endportion of the assembly. In an exemplary embodiment, the predeterminedportion of the assembly comprises a plurality of predetermined portionsof the assembly. In an exemplary embodiment, the predetermined portionof the assembly comprises a plurality of spaced apart predeterminedportions of the assembly. In an exemplary embodiment, the other portionof the assembly comprises an end portion of the assembly. In anexemplary embodiment, the other portion of the assembly comprises aplurality of other portions of the assembly. In an exemplary embodiment,the other portion of the assembly comprises a plurality of spaced apartother portions of the assembly. In an exemplary embodiment, the assemblycomprises a plurality of tubular members coupled to one another bycorresponding tubular couplings. In an exemplary embodiment, the tubularcouplings comprise the predetermined portions of the assembly; andwherein the tubular members comprise the other portion of the assembly.In an exemplary embodiment, one or more of the tubular couplingscomprise the predetermined portions of the assembly. In an exemplaryembodiment, one or more of the tubular members comprise thepredetermined portions of the assembly. In an exemplary embodiment, thepredetermined portion of the assembly defines one or more openings. Inan exemplary embodiment, one or more of the openings comprise slots. Inan exemplary embodiment, the anisotropy for the predetermined portion ofthe assembly is greater than 1. In an exemplary embodiment, theanisotropy for the predetermined portion of the assembly is greaterthan 1. In an exemplary embodiment, the strain hardening exponent forthe predetermined portion of the assembly is greater than 0.12. In anexemplary embodiment, the anisotropy for the predetermined portion ofthe assembly is greater than 1; and wherein the strain hardeningexponent for the predetermined portion of the assembly is greater than0.12. In an exemplary embodiment, the predetermined portion of theassembly comprises a first steel alloy comprising: 0.065% C, 1.44% Mn,0.01% P, 0.002% S, 0.24% Si, 0.01% Cu, 0.01% Ni, and 0.02% Cr. In anexemplary embodiment, the yield point of the predetermined portion ofthe assembly is at most about 46.9 ksi prior to the radial expansion andplastic deformation; and wherein the yield point of the predeterminedportion of the assembly is at least about 65.9 ksi after the radialexpansion and plastic deformation. In an exemplary embodiment, the yieldpoint of the predetermined portion of the assembly after the radialexpansion and plastic deformation is at least about 40% greater than theyield point of the predetermined portion of the assembly prior to theradial expansion and plastic deformation. In an exemplary embodiment,the anisotropy of the predetermined portion of the assembly, prior tothe radial expansion and plastic deformation, is about 1.48. In anexemplary embodiment, the predetermined portion of the assemblycomprises a second steel alloy comprising: 0.18% C, 1.28% Mn, 0.017% P,0.004% S, 0.29% Si, 0.01% Cu, 0.01% Ni, and 0.03% Cr. In an exemplaryembodiment, the yield point of the predetermined portion of the assemblyis at most about 57.8 ksi prior to the radial expansion and plasticdeformation; and wherein the yield point of the predetermined portion ofthe assembly is at least about 74.4 ksi after the radial expansion andplastic deformation. In an exemplary embodiment, the yield point of thepredetermined portion of the assembly after the radial expansion andplastic deformation is at least about 28% greater than the yield pointof the predetermined portion of the assembly prior to the radialexpansion and plastic deformation. In an exemplary embodiment, theanisotropy of the predetermined portion of the assembly, prior to theradial expansion and plastic deformation, is about 1.04. In an exemplaryembodiment, the predetermined portion of the assembly comprises a thirdsteel alloy comprising: 0.08% C, 0.82% Mn, 0.006% P, 0.003% S, 0.30% Si,0.16% Cu, 0.05% Ni, and 0.05% Cr. In an exemplary embodiment, theanisotropy of the predetermined portion of the assembly, prior to theradial expansion and plastic deformation, is about 1.92. In an exemplaryembodiment, the predetermined portion of the assembly comprises a fourthsteel alloy comprising: 0.02% C, 1.31% Mn, 0.02% P, 0.001% S, 0.45% Si,9.1% Ni, and 18.7% Cr. In an exemplary embodiment, the anisotropy of thepredetermined portion of the assembly, prior to the radial expansion andplastic deformation, is about 1.34. In an exemplary embodiment, theyield point of the predetermined portion of the assembly is at mostabout 46.9 ksi prior to the radial expansion and plastic deformation;and wherein the yield point of the predetermined portion of the assemblyis at least about 65.9 ksi after the radial expansion and plasticdeformation. In an exemplary embodiment, the yield point of thepredetermined portion of the assembly after the radial expansion andplastic deformation is at least about 40% greater than the yield pointof the predetermined portion of the assembly prior to the radialexpansion and plastic deformation. In an exemplary embodiment, theanisotropy of the predetermined portion of the assembly, prior to theradial expansion and plastic deformation, is at least about 1.48. In anexemplary embodiment, the yield point of the predetermined portion ofthe assembly is at most about 57.8 ksi prior to the radial expansion andplastic deformation; and wherein the yield point of the predeterminedportion of the assembly is at least about 74.4 ksi after the radialexpansion and plastic deformation. In an exemplary embodiment, the yieldpoint of the predetermined portion of the assembly after the radialexpansion and plastic deformation is at least about 28% greater than theyield point of the predetermined portion of the assembly prior to theradial expansion and plastic deformation. In an exemplary embodiment,the anisotropy of the predetermined portion of the assembly, prior tothe radial expansion and plastic deformation, is at least about 1.04. Inan exemplary embodiment, the anisotropy of the predetermined portion ofthe assembly, prior to the radial expansion and plastic deformation, isat least about 1.92. In an exemplary embodiment, the anisotropy of thepredetermined portion of the assembly, prior to the radial expansion andplastic deformation, is at least about 1.34. In an exemplary embodiment,the anisotropy of the predetermined portion of the assembly, prior tothe radial expansion and plastic deformation, ranges from about 1.04 toabout 1.92. In an exemplary embodiment, the yield point of thepredetermined portion of the assembly, prior to the radial expansion andplastic deformation, ranges from about 47.6 ksi to about 61.7 ksi. In anexemplary embodiment, the expandability coefficient of the predeterminedportion of the assembly, prior to the radial expansion and plasticdeformation, is greater than 0.12. In an exemplary embodiment, theexpandability coefficient of the predetermined portion of the assemblyis greater than the expandability coefficient of the other portion ofthe assembly. In an exemplary embodiment, the assembly comprises awellbore casing. In an exemplary embodiment, the assembly comprises apipeline. In an exemplary embodiment, the assembly comprises astructural support. In an exemplary embodiment, the annulus is at leastpartially defined by an irregular surface. In an exemplary embodiment,the annulus is at least partially defined by a toothed surface. In anexemplary embodiment, the sealing element comprises an elastomericmaterial. In an exemplary embodiment, the sealing element comprises ametallic material. In an exemplary embodiment, the sealing elementcomprises an elastomeric and a metallic material.

A method of joining radially expandable tubular members is provided thatincludes providing a first tubular member; providing a second tubularmember; providing a sleeve; mounting the sleeve for overlapping andcoupling the first and second tubular members; threadably coupling thefirst and second tubular members at a first location; threadablycoupling the first and second tubular members at a second locationspaced apart from the first location; sealing an interface between thefirst and second tubular members between the first and second locationsusing a compressible sealing element, wherein the first tubular member,second tubular member, sleeve, and the sealing element define a tubularassembly; and radially expanding and plastically deforming the tubularassembly; wherein, prior to the radial expansion and plasticdeformation, a predetermined portion of the tubular assembly has a loweryield point than another portion of the tubular assembly. In anexemplary embodiment, the sealing element includes an irregular surface.In an exemplary embodiment, the sealing element includes a toothedsurface. In an exemplary embodiment, the sealing element comprises anelastomeric material. In an exemplary embodiment, the sealing elementcomprises a metallic material. In an exemplary embodiment, the sealingelement comprises an elastomeric and a metallic material. In anexemplary embodiment, the predetermined portion of the tubular assemblyhas a higher ductility and a lower yield point prior to the radialexpansion and plastic deformation than after the radial expansion andplastic deformation. In an exemplary embodiment, the predeterminedportion of the tubular assembly has a higher ductility prior to theradial expansion and plastic deformation than after the radial expansionand plastic deformation. In an exemplary embodiment, the predeterminedportion of the tubular assembly has a lower yield point prior to theradial expansion and plastic deformation than after the radial expansionand plastic deformation. In an exemplary embodiment, the predeterminedportion of the tubular assembly has a larger inside diameter after theradial expansion and plastic deformation than the other portion of thetubular assembly. In an exemplary embodiment, the method furtherincludes: positioning another tubular assembly within the preexistingstructure in overlapping relation to the tubular assembly; and radiallyexpanding and plastically deforming the other tubular assembly withinthe preexisting structure; wherein, prior to the radial expansion andplastic deformation of the tubular assembly, a predetermined portion ofthe other tubular assembly has a lower yield point than another portionof the other tubular assembly. In an exemplary embodiment, the insidediameter of the radially expanded and plastically deformed other portionof the tubular assembly is equal to the inside diameter of the radiallyexpanded and plastically deformed other portion of the other tubularassembly. In an exemplary embodiment, the predetermined portion of thetubular assembly comprises an end portion of the tubular assembly. In anexemplary embodiment, the predetermined portion of the tubular assemblycomprises a plurality of predetermined portions of the tubular assembly.In an exemplary embodiment, the predetermined portion of the tubularassembly comprises a plurality of spaced apart predetermined portions ofthe tubular assembly. In an exemplary embodiment, the other portion ofthe tubular assembly comprises an end portion of the tubular assembly.In an exemplary embodiment, the other portion of the tubular assemblycomprises a plurality of other portions of the tubular assembly. In anexemplary embodiment, the other portion of the tubular assemblycomprises a plurality of spaced apart other portions of the tubularassembly. In an exemplary embodiment, the tubular assembly comprises aplurality of tubular members coupled to one another by correspondingtubular couplings. In an exemplary embodiment, the tubular couplingscomprise the predetermined portions of the tubular assembly; and whereinthe tubular members comprise the other portion of the tubular assembly.In an exemplary embodiment, one or more of the tubular couplingscomprise the predetermined portions of the tubular assembly. In anexemplary embodiment, one or more of the tubular members comprise thepredetermined portions of the tubular assembly. In an exemplaryembodiment, the predetermined portion of the tubular assembly definesone or more openings. In an exemplary embodiment, one or more of theopenings comprise slots. In an exemplary embodiment, the anisotropy forthe predetermined portion of the tubular assembly is greater than 1. Inan exemplary embodiment, the anisotropy for the predetermined portion ofthe tubular assembly is greater than 1. In an exemplary embodiment, thestrain hardening exponent for the predetermined portion of the tubularassembly is greater than 0.12. In an exemplary embodiment, theanisotropy for the predetermined portion of the tubular assembly isgreater than 1; and wherein the strain hardening exponent for thepredetermined portion of the tubular assembly is greater than 0.12. Inan exemplary embodiment, the predetermined portion of the tubularassembly comprises a first steel alloy comprising: 0.065% C, 1.44% Mn,0.01% P, 0.002% S, 0.24% Si, 0.01% Cu, 0.01% Ni, and 0.02% Cr. In anexemplary embodiment, the yield point of the predetermined portion ofthe tubular assembly is at most about 46.9 ksi prior to the radialexpansion and plastic deformation; and wherein the yield point of thepredetermined portion of the tubular assembly is at least about 65.9 ksiafter the radial expansion and plastic deformation. In an exemplaryembodiment, the yield point of the predetermined portion of the tubularassembly after the radial expansion and plastic deformation is at leastabout 40% greater than the yield point of the predetermined portion ofthe tubular assembly prior to the radial expansion and plasticdeformation. In an exemplary embodiment, the anisotropy of thepredetermined portion of the tubular assembly, prior to the radialexpansion and plastic deformation, is about 1.48. In an exemplaryembodiment, the predetermined portion of the tubular assembly comprisesa second steel alloy comprising: 0.18% C, 1.28% Mn, 0.017% P, 0.004% S,0.29% Si, 0.01% Cu, 0.01% Ni, and 0.03% Cr. In an exemplary embodiment,the yield point of the predetermined portion of the tubular assembly isat most about 57.8 ksi prior to the radial expansion and plasticdeformation; and wherein the yield point of the predetermined portion ofthe tubular assembly is at least about 74.4 ksi after the radialexpansion and plastic deformation. In an exemplary embodiment, the yieldpoint of the predetermined portion of the tubular assembly after theradial expansion and plastic deformation is at least about 28% greaterthan the yield point of the predetermined portion of the tubularassembly prior to the radial expansion and plastic deformation. In anexemplary embodiment, the anisotropy of the predetermined portion of thetubular assembly, prior to the radial expansion and plastic deformation,is about 1.04. In an exemplary embodiment, the predetermined portion ofthe tubular assembly comprises a third steel alloy comprising: 0.08% C,0.82% Mn, 0.006% P, 0.003% S, 0.30% Si, 0.16% Cu, 0.05% Ni, and 0.05%Cr. In an exemplary embodiment, the anisotropy of the predeterminedportion of the tubular assembly, prior to the radial expansion andplastic deformation, is about 1.92. In an exemplary embodiment, thepredetermined portion of the tubular assembly comprises a fourth steelalloy comprising: 0.02% C, 1.31% Mn, 0.02% P, 0.001% S, 0.45% Si, 9.1%Ni, and 18.7% Cr. In an exemplary embodiment, the anisotropy of thepredetermined portion of the tubular assembly, prior to the radialexpansion and plastic deformation, is about 1.34. In an exemplaryembodiment, the yield point of the predetermined portion of the tubularassembly is at most about 46.9 ksi prior to the radial expansion andplastic deformation; and wherein the yield point of the predeterminedportion of the tubular assembly is at least about 65.9 ksi after theradial expansion and plastic deformation. In an exemplary embodiment,the yield point of the predetermined portion of the tubular assemblyafter the radial expansion and plastic deformation is at least about 40%greater than the yield point of the predetermined portion of the tubularassembly prior to the radial expansion and plastic deformation. In anexemplary embodiment, the anisotropy of the predetermined portion of thetubular assembly, prior to the radial expansion and plastic deformation,is at least about 1.48. In an exemplary embodiment, the yield point ofthe predetermined portion of the tubular assembly is at most about 57.8ksi prior to the radial expansion and plastic deformation; and whereinthe yield point of the predetermined portion of the tubular assembly isat least about 74.4 ksi after the radial expansion and plasticdeformation. In an exemplary embodiment, the yield point of thepredetermined portion of the tubular assembly after the radial expansionand plastic deformation is at least about 28% greater than the yieldpoint of the predetermined portion of the tubular assembly prior to theradial expansion and plastic deformation. In an exemplary embodiment,the anisotropy of the predetermined portion of the tubular assembly,prior to the radial expansion and plastic deformation, is at least about1.04. In an exemplary embodiment, the anisotropy of the predeterminedportion of the tubular assembly, prior to the radial expansion andplastic deformation, is at least about 1.92. In an exemplary embodiment,the anisotropy of the predetermined portion of the tubular assembly,prior to the radial expansion and plastic deformation, is at least about1.34. In an exemplary embodiment, the anisotropy of the predeterminedportion of the tubular assembly, prior to the radial expansion andplastic deformation, ranges from about 1.04 to about 1.92. In anexemplary embodiment, the yield point of the predetermined portion ofthe tubular assembly, prior to the radial expansion and plasticdeformation, ranges from about 47.6 ksi to about 61.7 ksi. In anexemplary embodiment, the expandability coefficient of the predeterminedportion of the tubular assembly, prior to the radial expansion andplastic deformation, is greater than 0.12. In an exemplary embodiment,the expandability coefficient of the predetermined portion of thetubular assembly is greater than the expandability coefficient of theother portion of the tubular assembly. In an exemplary embodiment, thetubular assembly comprises a wellbore casing. In an exemplaryembodiment, the tubular assembly comprises a pipeline. In an exemplaryembodiment, the tubular assembly comprises a structural support. In anexemplary embodiment, the sleeve comprises: a plurality of spaced aparttubular sleeves coupled to and receiving end portions of the first andsecond tubular members. In an exemplary embodiment, the first tubularmember comprises a first threaded connection; wherein the second tubularmember comprises a second threaded connection; wherein the first andsecond threaded connections are coupled to one another; wherein at leastone of the tubular sleeves is positioned in opposing relation to thefirst threaded connection; and wherein at least one of the tubularsleeves is positioned in opposing relation to the second threadedconnection. In an exemplary embodiment, the first tubular membercomprises a first threaded connection; wherein the second tubular membercomprises a second threaded connection; wherein the first and secondthreaded connections are coupled to one another; and wherein at leastone of the tubular sleeves is not positioned in opposing relation to thefirst and second threaded connections. In an exemplary embodiment, thecarbon content of the tubular member is less than or equal to 0.12percent; and wherein the carbon equivalent value for the tubular memberis less than 0.21. In an exemplary embodiment, the tubular membercomprises a wellbore casing.

An expandable tubular member has been described, wherein the carboncontent of the tubular member is greater than 0.12 percent; and whereinthe carbon equivalent value for the tubular member is less than 0.36. Inan exemplary embodiment, the tubular member comprises a wellbore casing.

A method of selecting tubular members for radial expansion and plasticdeformation has been described that includes: selecting a tubular memberfrom a collection of tubular member; determining a carbon content of theselected tubular member; determining a carbon equivalent value for theselected tubular member; and if the carbon content of the selectedtubular member is less than or equal to 0.12 percent and the carbonequivalent value for the selected tubular member is less than 0.21, thendetermining that the selected tubular member is suitable for radialexpansion and plastic deformation.

A method of selecting tubular members for radial expansion and plasticdeformation has been described that includes: selecting a tubular memberfrom a collection of tubular member; determining a carbon content of theselected tubular member; determining a carbon equivalent value for theselected tubular member; and if the carbon content of the selectedtubular member is greater than 0.12 percent and the carbon equivalentvalue for the selected tubular member is less than 0.36, thendetermining that the selected tubular member is suitable for radialexpansion and plastic deformation.

An expandable tubular member has been described that includes: a tubularbody; wherein a yield point of an inner tubular portion of the tubularbody is less than a yield point of an outer tubular portion of thetubular body. In an exemplary embodiment, the yield point of the innertubular portion of the tubular body varies as a function of the radialposition within the tubular body. In an exemplary embodiment, the yieldpoint of the inner tubular portion of the tubular body varies in anlinear fashion as a function of the radial position within the tubularbody. In an exemplary embodiment, the yield point of the inner tubularportion of the tubular body varies in an non-linear fashion as afunction of the radial position within the tubular body. In an exemplaryembodiment, the yield point of the outer tubular portion of the tubularbody varies as a function of the radial position within the tubularbody. In an exemplary embodiment, the yield point of the outer tubularportion of the tubular body varies in an linear fashion as a function ofthe radial position within the tubular body. In an exemplary embodiment,the yield point of the outer tubular portion of the tubular body variesin an non-linear fashion as a function of the radial position within thetubular body. In an exemplary embodiment, the yield point of the innertubular portion of the tubular body varies as a function of the radialposition within the tubular body; and wherein the yield point of theouter tubular portion of the tubular body varies as a function of theradial position within the tubular body. In an exemplary embodiment, theyield point of the inner tubular portion of the tubular body varies in alinear fashion as a function of the radial position within the tubularbody; and wherein the yield point of the outer tubular portion of thetubular body varies in a linear fashion as a function of the radialposition within the tubular body. In an exemplary embodiment, the yieldpoint of the inner tubular portion of the tubular body varies in alinear fashion as a function of the radial position within the tubularbody; and wherein the yield point of the outer tubular portion of thetubular body varies in a non-linear fashion as a function of the radialposition within the tubular body. In an exemplary embodiment, the yieldpoint of the inner tubular portion of the tubular body varies in anon-linear fashion as a function of the radial position within thetubular body; and wherein the yield point of the outer tubular portionof the tubular body varies in a linear fashion as a function of theradial position within the tubular body. In an exemplary embodiment, theyield point of the inner tubular portion of the tubular body varies in anon-linear fashion as a function of the radial position within thetubular body; and wherein the yield point of the outer tubular portionof the tubular body varies in a non-linear fashion as a function of theradial position within the tubular body. In an exemplary embodiment, therate of change of the yield point of the inner tubular portion of thetubular body is different than the rate of change of the yield point ofthe outer tubular portion of the tubular body. In an exemplaryembodiment, the rate of change of the yield point of the inner tubularportion of the tubular body is different than the rate of change of theyield point of the outer tubular portion of the tubular body.

A method of manufacturing an expandable tubular member has beendescribed that includes: providing a tubular member; heat treating thetubular member; and quenching the tubular member; wherein following thequenching, the tubular member comprises a microstructure comprising ahard phase structure and a soft phase structure. In an exemplaryembodiment, the provided tubular member comprises, by weight percentage,0.065% C, 1.44% Mn, 0.01% P, 0.002% S, 0.24% Si, 0.01% Cu, 0.01% Ni,0.02% Cr, 0.05% V, 0.01% Mo, 0.01% Nb, and 0.01% Ti. In an exemplaryembodiment, the provided tubular member comprises, by weight percentage,0.18% C, 1.28% Mn, 0.017% P, 0.004% S, 0.29% Si, 0.01% Cu, 0.01% Ni,0.03% Cr, 0.04% V, 0.01% Mo, 0.03% Nb, and 0.01% Ti. In an exemplaryembodiment, the provided tubular member comprises, by weight percentage,0.08% C, 0.82% Mn, 0.006% P, 0.003% S, 0.30% Si, 0.06% Cu, 0.05% Ni,0.05% Cr, 0.03% V, 0.03% Mo, 0.01% Nb, and 0.01% Ti. In an exemplaryembodiment, the provided tubular member comprises a microstructurecomprising one or more of the following: martensite, pearlite, vanadiumcarbide, nickel carbide, or titanium carbide. In an exemplaryembodiment, the provided tubular member comprises a microstructurecomprising one or more of the following: pearlite or pearlite striation.In an exemplary embodiment, the provided tubular member comprises amicrostructure comprising one or more of the following: grain pearlite,widmanstatten martensite, vanadium carbide, nickel carbide, or titaniumcarbide. In an exemplary embodiment, the heat treating comprises heatingthe provided tubular member for about 10 minutes at 790° C. In anexemplary embodiment, the quenching comprises quenching the heat treatedtubular member in water. In an exemplary embodiment, following thequenching, the tubular member comprises a microstructure comprising oneor more of the following: ferrite, grain pearlite, or martensite. In anexemplary embodiment, following the quenching, the tubular membercomprises a microstructure comprising one or more of the following:ferrite, martensite, or bainite. In an exemplary embodiment, followingthe quenching, the tubular member comprises a microstructure comprisingone or more of the following: bainite, pearlite, or ferrite. In anexemplary embodiment, following the quenching, the tubular membercomprises a yield strength of about 67 ksi and a tensile strength ofabout 95 ksi. In an exemplary embodiment, following the quenching, thetubular member comprises a yield strength of about 82 ksi and a tensilestrength of about 130 ksi. In an exemplary embodiment, following thequenching, the tubular member comprises a yield strength of about 60 ksiand a tensile strength of about 97 ksi. In an exemplary embodiment, themethod further includes: positioning the quenched tubular member withina preexisting structure; and radially expanding and plasticallydeforming the tubular member within the preexisting structure.

A system for radially expanding and plastically deforming a tubularmember has been described that includes an expansion device positionedin the tubular member, wherein the coefficient of friction between theexpansion device and the tubular member during radial expansion andplastic deformation is less than 0.08. In an exemplary embodiment, thecoefficient of friction is in the range of 0.02 to 0.05. In an exemplaryembodiment, the system includes a lubricant between the tubular memberand the expansion device. In an exemplary embodiment, the lubricantincludes oil based lubricants, H1 oil, H2 oil, H3 oil, H4 oil, H5 oil,H6 oil, H7 oil, grease, water based lubricants, drilling mud, drillingmud and solid lubricants, grease combined with a solid lubricant, atleast 10% Graphite, or at least 10% Molybdenum Disulfide. In anexemplary embodiment, the system includes a coating on the expansiondevice. In an exemplary embodiment, the coating may be Phygen film. Inan exemplary embodiment, the system includes a coating on the tubularmember. In an exemplary embodiment, the coating on the tubular memberincludes PTFE, PTFE based or graphite based. In an exemplary embodiment,the expansion device includes DC53 material, DC2 material, DC3 material,DC5 material, DC7 material, M2 material, CPM M4 material, 10V material,3V material. In an exemplary embodiment, the expansion device includesan REM finish, a processed finish, or a relatively smooth surfaceroughness. In an exemplary embodiment, the expansion device includes arelatively smooth surface roughness and includes relatively evenly spaceoil pockets. In an exemplary embodiment, the expansion device includes asmooth surface roughness in the range of 0.02 to 0.1 micrometers In anexemplary embodiment, the lubricant is injected through at least aportion of the expansion device between the tubular member and theexpansion device. In an exemplary embodiment, the lubricant is injectedthrough at least a portion of the expansion device between the tubularmember and the expansion device when a predetermined pressure is met. Inan exemplary embodiment, the lubricant is injected through at least twoportions of the expansion device between the tubular member and theexpansion device at two different pressures. In an exemplary embodiment,the expansion device includes a tapered portion with an outer surface,internal flow passage in the tapered portion and at least onecircumferential groove having a first edge and a second edge having witha sliding angle on the outer surface of the tapered portion fluidiclycoupled to the internal flow passage for receiving lubricant duringradial expansion and plastic deformation of the tubular member, whereinthe sliding angle is less than or equal to 30 degrees. In an exemplaryembodiment, the expansion device includes a tapered portion with anouter surface, internal flow passage in the tapered portion, and atleast one circumferential groove having a first edge and a second edgehaving with a sliding angle on the outer surface of the tapered portionfluidicly coupled to the internal flow passage for receiving lubricantduring radial expansion and plastic deformation of the tubular member,wherein the sliding angle is less than or equal to 10 degrees. In anexemplary embodiment, the system includes a lubricant between thetubular member and the expansion device, comprising at least ninecomponents selected from the group consisting of: a base oil; metaldeactivator; antioxidants; sulfurized natural oils; phosphate ester;phosphoric acid; viscosity modifier; pour-point depressant; defoamer;and carboxylic acid soaps. In an exemplary embodiment, the expansiondevice includes, a tapered portion having a tapered faceted polygonalouter expansion surface. In an exemplary embodiment, the tubular memberhas a non-uniform wall thickness and the expansion device includes atapered portion having a tapered faceted polygonal outer expansionsurface. In an exemplary embodiment, the lubricant is stored in areservoir with electrodes that are electrically coupled a capacitor inthe expansion device and is injected through at least a portion of theexpansion device between the tubular member and the expansion devicewhen the capacitors discharges. In an exemplary embodiment, theexpansion device includes a wellbore casing, a pipeline, or a structuralsupport. In an exemplary embodiment, the expansion device includesexpansion cone.

A method of radially expanding and plastically deforming a tubularmember has been described that includes positioning an expansion devicehaving a first tapered end and a second end at least partially withinthe tubular member, displacing the expansion device relative to thetubular member to radially expand and plastically deform the tubularmember, and wherein the coefficient of friction between the expansiondevice and the tubular member during radial expansion and plasticdeformation is less than 0.08. In an exemplary embodiment, thecoefficient of friction is in the range of 0.02 to 0.05. In an exemplaryembodiment, the method includes injecting lubricant between the tubularmember and the expansion device. In an exemplary embodiment, thelubricant includes oil based lubricants, H1 oil, H2 oil, H3 oil, H4 oil,H5 oil, H6 oil, H7 oil, grease, water based lubricants, drilling mud,drilling mud and solid lubricants, grease combined with a solidlubricant, at least 10% Graphite, or at least 10% Molybdenum Disulfide.In an exemplary embodiment, the method includes applying a coating onthe expansion device prior to positioning within the tubular member. Inan exemplary embodiment, the coating may be Phygen film. In an exemplaryembodiment, the method includes applying a coating on the tubular memberprior to positioning the expansion device within the tubular member. Inan exemplary embodiment, the coating on the tubular member includesPTFE, PTFE based or graphite based. In an exemplary embodiment, theexpansion device includes DC53 material, DC2 material, DC3 material, DC5material, DC7 material, M2 material, CPM M4 material, 10V material, 3Vmaterial. In an exemplary embodiment, the expansion device includes anREM finish, a processed finish, or a relatively smooth surfaceroughness. In an exemplary embodiment, the expansion device includes arelatively smooth surface roughness and includes relatively evenly spaceoil pockets. In an exemplary embodiment, the expansion device includes asmooth surface roughness in the range of 0.02 to 0.1 micrometers In anexemplary embodiment, the method includes injecting lubricant through atleast a portion of the expansion device between the tubular member andthe expansion device. In an exemplary embodiment, the method includesinjecting lubricant through at least a portion of the expansion devicebetween the tubular member and the expansion device when a predeterminedpressure is met. In an exemplary embodiment, the method includesinjecting lubricant through at least two portions of the expansiondevice between the tubular member and the expansion device at twodifferent pressures. In an exemplary embodiment, the expansion deviceincludes a tapered portion with an outer surface, internal flow passagein the tapered portion and at least one circumferential groove having afirst edge and a second edge having with a sliding angle on the outersurface of the tapered portion fluidicly coupled to the internal flowpassage for receiving lubricant during radial expansion and plasticdeformation of the tubular member, wherein the sliding angle is lessthan or equal to 30 degrees. In an exemplary embodiment, the expansiondevice includes a tapered portion with an outer surface, internal flowpassage in the tapered portion, and at least one circumferential groovehaving a first edge and a second edge having with a sliding angle on theouter surface of the tapered portion fluidicly coupled to the internalflow passage for receiving lubricant during radial expansion and plasticdeformation of the tubular member, wherein the sliding angle is lessthan or equal to 10 degrees. In an exemplary embodiment, the methodincludes injecting lubricant between the tubular member and theexpansion device, comprising at least nine components selected from thegroup consisting of: a base oil; metal deactivator; antioxidants;sulfurized natural oils; phosphate ester; phosphoric acid; viscositymodifier; pour-point depressant; defoamer; and carboxylic acid soaps. Inan exemplary embodiment, the expansion device includes a tapered portionhaving a tapered faceted polygonal outer expansion surface. In anexemplary embodiment, the expansion device includes, a tapered portionhaving a tapered faceted polygonal outer expansion surface. In anexemplary embodiment, the tubular member has a non-uniform wallthickness and the expansion device includes a tapered portion having atapered faceted polygonal outer expansion surface. In an exemplaryembodiment, the lubricant is stored in a reservoir with electrodes thatare electrically coupled a capacitor in the expansion device and isinjected through at least a portion of the expansion device between thetubular member and the expansion device when the capacitors discharges.In an exemplary embodiment, the expansion device includes a wellborecasing, a pipeline, or a structural support. In an exemplary embodiment,the expansion device includes expansion cone.

A system for radially expanding and plastically deforming a tubularmember has been described that includes means for positioning anexpansion device having a first tapered end and a second end at leastpartially within the tubular member and means for displacing theexpansion device relative to the tubular member to radially expand andplastically deform the tubular member, wherein the coefficient offriction between the expansion device and the tubular member duringradial expansion and plastic deformation is less than 0.08. In anexemplary embodiment, the coefficient of friction is in the range of0.02 to 0.05. In an exemplary embodiment, the system, includes a meansfor injecting lubricant between the tubular member and the expansiondevice. In an exemplary embodiment, the lubricant includes oil basedlubricants, H1 oil, H2 oil, H3 oil, H4 oil, H5 oil, H6 oil, H7 oil,grease, water based lubricants, drilling mud, drilling mud and solidlubricants, grease combined with a solid lubricant, at least 10%Graphite, or at least 10% Molybdenum Disulfide. In an exemplaryembodiment, the system includes a means for applying a coating on theexpansion device prior to positioning within the tubular member. In anexemplary embodiment, the coating may be Phygen film. In an exemplaryembodiment, the method includes applying a coating on the tubular memberprior to positioning the expansion device within the tubular member. Inan exemplary embodiment, the coating on the tubular member includesPTFE, PTFE based or graphite based. In an exemplary embodiment, theexpansion device includes DC53 material, DC2 material, DC3 material, DC5material, DC7 material, M2 material, CPM M4 material, 10V material, 3Vmaterial. In an exemplary embodiment, the expansion device includes anREM finish, a processed finish, or a relatively smooth surfaceroughness. In an exemplary embodiment, the expansion device includes arelatively smooth surface roughness and includes relatively evenly spaceoil pockets. In an exemplary embodiment, the expansion device includes asmooth surface roughness in the range of 0.02 to 0.1 micrometers In anexemplary embodiment, the system includes a means for injectinglubricant through at least a portion of the expansion device between thetubular member and the expansion device. In an exemplary embodiment, thesystem includes a means for injecting lubricant through at least aportion of the expansion device between the tubular member and theexpansion device when a predetermined pressure is met. In an exemplaryembodiment, the system includes a means for injecting lubricant throughat least two portions of the expansion device between the tubular memberand the expansion device at two different pressures. In an exemplaryembodiment, the expansion device includes a tapered portion with anouter surface, internal flow passage in the tapered portion and at leastone circumferential groove having a first edge and a second edge havingwith a sliding angle on the outer surface of the tapered portionfluidicly coupled to the internal flow passage for receiving lubricantduring radial expansion and plastic deformation of the tubular member,wherein the sliding angle is less than or equal to 30 degrees. In anexemplary embodiment, the expansion device includes a tapered portionwith an outer surface, internal flow passage in the tapered portion, andat least one circumferential groove having a first edge and a secondedge having with a sliding angle on the outer surface of the taperedportion fluidicly coupled to the internal flow passage for receivinglubricant during radial expansion and plastic deformation of the tubularmember, wherein the sliding angle is less than or equal to 10 degrees.In an exemplary embodiment, the system includes a means for injectinglubricant between the tubular member and the expansion device,comprising at least nine components selected from the group consistingof: a base oil; metal deactivator; antioxidants; sulfurized naturaloils; phosphate ester; phosphoric acid; viscosity modifier; pour-pointdepressant; defoamer; and carboxylic acid soaps. In an exemplaryembodiment, the expansion device includes a tapered portion having atapered faceted polygonal outer expansion surface. In an exemplaryembodiment, the expansion device includes, a tapered portion having atapered faceted polygonal outer expansion surface. In an exemplaryembodiment, the tubular member has a non-uniform wall thickness and theexpansion device includes a tapered portion having a tapered facetedpolygonal outer expansion surface. In an exemplary embodiment, thelubricant is stored in a reservoir with electrodes that are electricallycoupled a capacitor in the expansion device and is injected through atleast a portion of the expansion device between the tubular member andthe expansion device when the capacitors discharges. In an exemplaryembodiment, the expansion device includes a wellbore casing, a pipeline,or a structural support. In an exemplary embodiment, the expansiondevice includes expansion cone.

A lubricant for injecting in an interface between a tubular member andan expansion device has been describe that includes at least eightcomponents selected from the group consisting of: a base oil; metaldeactivator; antioxidants; sulfurized natural oils; phosphate ester;phosphoric acid; viscosity modifier; pour-point depressant; defoamer;and carboxylic acid soaps. In an exemplary embodiment, the lubricant byweight includes: 64.25-90.89% base oil; 0.02-0.05% metal deactivator;0.5-3.0% antioxidants; 4-12% sulfurized natural oils; 4-12% phosphateester; 0.4-1.5% phosphoric acid; 0.08-1.5% viscosity modifier; 0.1-0.5%pour-point depressant; 0.01-0.2% defoamer; and 0-5% carboxylic acidsoaps.

A lubricant for injecting in an interface between a tubular member andan expansion device has been described that includes 77.81% canola oil;0.04% tolyltriazole; 1.0% phenolic antioxidant; 10% sulfurized naturaloil or sulferized lard oil; 9% phosphate ester; 1% phosphoric acid; 0.8%styrene hydrocarbon polymer; 0.3% alkyl ester copolymer; and 0.05%silicon based antifoam agent.

A lubricant for injecting in an interface between a tubular member andan expansion device has been described that includes: 64.25% canola oil;0.05% tolyltriazole; 1.0% aminic antioxidant; 2.0% phenolic antioxidant,12% sulfurized natural oil or sulferized lard oil; 12% phosphate ester;1.5% phosphoric acid; 1.5% styrene hydrocarbon polymer; 0.5% alkyl estercopolymer; 0.2% silicon based antifoam agent, and 5% carbozylic acidsoap.

A lubricant for injecting in an interface between a tubular member andan expansion device has been described that includes: 90.89% canola oil;0.02% tolyltriazole; 0.5% phenolic antioxidant; 4% sulfurized naturaloil or sulferized lard oil; 4% phosphate ester; 0.4% phosphoric acid;0.08% styrene hydrocarbon polymer; 0.1% alkyl ester copolymer; and 0.01%silicon based antifoam agent.

A lubricant for injecting in an interface between a tubular member andan expansion device has been described that includes: 68.71% canola oil;0.04% tolyltriazole; 0.5% aminic antioxidant, 1.0% phenolic antioxidant;12% sulfurized natural oil or sulferized lard oil; 10% phosphate ester;1.1% phosphoric acid; 1.5% styrene hydrocarbon polymer; 0.1% alkyl estercopolymer; 0.05% silicon based antifoam agent, and 5% carbozylic acidsoap.

A lubricant for injecting in an interface between a tubular member andan expansion device has been described that includes: 82.07% canola oil;0.03% tolyltriazole; 0.5% aminic antioxidant, 0.5% phenolic antioxidant;10% sulfurized natural oil or sulferized lard oil; 5% phosphate ester;0.5% phosphoric acid; 0.1% styrene hydrocarbon polymer; 0.2% alkyl estercopolymer; 0.1% silicon based antifoam agent, and 1% carbozylic acidsoap.

A lubricant for injecting in an interface between a tubular member andan expansion device has been described that includes: 80.68% canola oil;0.04% tolyltriazole; 1% phenolic antioxidant; 8% sulfurized natural oilor sulferized lard oil; 9% phosphate ester; 1% phosphoric acid; 0.1%styrene hydrocarbon polymer; 0.1% alkyl ester copolymer; and 0.08%silicon based antifoam agent.

A lubricant for injecting in an interface between a tubular member andan expansion device has been described that includes: 80.31% canola oil;0.04% tolyltriazole; 1.1% phenolic antioxidant; 9% sulfurized naturaloil or sulferized lard oil; 8% phosphate ester; 0.8% phosphoric acid;0.4% styrene hydrocarbon polymer; 0.3% alkyl ester copolymer; and 0.05%silicon based antifoam agent.

A lubricant for injecting in an interface between a tubular member andan expansion device has been described that includes: at least 10%Graphite.

A lubricant for injecting in an interface between a tubular member andan expansion device has been described that includes: at least 10%Molybedenum Disulfide in a thickener in with a dropping point above350-400 F.

An expansion device for radially expanding and plastically deforming thetubular member has been described that includes one or more expansionsurfaces on the expansion device for engaging the interior surface ofthe tubular member during the radial expansion and plastic deformationof the tubular member; and a lubrication device operably coupled to theexpansion surface for injecting lubricant into an interface between theexpansion surface and the tubular member during the radial expansion andplastic deformation of the tubular member when a predetermined pressurefor lubrication is reached. In an exemplary embodiment, the lubricationdevice includes a pump. In an exemplary embodiment, the lubricationdevice includes a reservoir operably coupled to the expansion surfacefor house a lubricant; a means for pressurizing the lubricant; and ameans for injecting the lubricant in the reservoir into the interfacewhen the predetermine pressure is reached. In an exemplary embodiment,the lubrication device includes a reservoir operably coupled to theexpansion surface for house a lubricant; a means for pressurizing thelubricant, and a valve fluidicly coupled to the reservoir and theexpansion surface for injecting the lubricant into the interface whenthe predetermine pressure is reached. In an exemplary embodiment, thelubrication device includes a reservoir operably coupled to theexpansion surface for house a lubricant, a means for pressurizing thelubricant, a pressure enhancer operably coupled to the reservoir toincrease the pressure on the lubricant in the reservoir, and a valvefluidicly coupled to the reservoir and the expansion surface forinjecting the lubricant into the interface when the predeterminepressure is reached. In an exemplary embodiment, the lubrication deviceincludes a reservoir operably coupled to the expansion surface for housea lubricant, a means for pressurizing the lubricant, a piston operablycoupled to the reservoir, and a valve fluidicly coupled to the reservoirand the expansion surface for injecting the lubricant into the interfacewhen the predetermine pressure is reached. In an exemplary embodiment,the coefficient of friction between the expansion device and the tubularmember during radial expansion and plastic deformation is less than0.08. In an exemplary embodiment, the lubrication device includes thecoefficient of friction between the expansion device and the tubularmember during radial expansion and plastic deformation is in the rangeof 0.02 to 0.05. In an exemplary embodiment, the lubricant includes oilbased lubricants, H1 oil, H2 oil, H3 oil, H4 oil, H5 oil, H6 oil, H7oil, grease, water based lubricants, drilling mud, drilling mud andsolid lubricants, grease combined with a solid lubricant, at least 10%Graphite, or at least 10% Molybdenum Disulfide. In an exemplaryembodiment, the expansion device includes a coating on the expansiondevice. In an exemplary embodiment, the coating may be Phygen film. Inan exemplary embodiment, the expansion device includes a coating on thetubular member. In an exemplary embodiment, the coating on the tubularmember includes PTFE, PTFE based or graphite based. In an exemplaryembodiment, the expansion device includes DC53 material, DC2 material,DC3 material, DC5 material, DC7 material, M2 material, CPM M4 material,10V material, 3V material. In an exemplary embodiment, the expansiondevice includes an REM finish, a processed finish, or a relativelysmooth surface roughness. In an exemplary embodiment, the expansiondevice includes a relatively smooth surface roughness and includesrelatively evenly space oil pockets. In an exemplary embodiment, theexpansion device includes a smooth surface roughness in the range of0.02 to 0.1 micrometers In an exemplary embodiment, the lubricant isinjected through at least a portion of the expansion device between thetubular member and the expansion device. In an exemplary embodiment, theexpansion device includes a means for injecting lubricant through atleast a portion of the expansion device between the tubular member andthe expansion device when a predetermined pressure is met. In anexemplary embodiment, the expansion device includes a means forinjecting lubricant through at least two portions of the expansiondevice between the tubular member and the expansion device at twodifferent pressures. In an exemplary embodiment, the expansion deviceincludes a tapered portion with an outer surface, internal flow passagein the tapered portion and at least one circumferential groove having afirst edge and a second edge having with a sliding angle on the outersurface of the tapered portion fluidicly coupled to the internal flowpassage for receiving lubricant during radial expansion and plasticdeformation of the tubular member, wherein the sliding angle is lessthan or equal to 30 degrees. In an exemplary embodiment, the expansiondevice includes a tapered portion with an outer surface, internal flowpassage in the tapered portion, and at least one circumferential groovehaving a first edge and a second edge having with a sliding angle on theouter surface of the tapered portion fluidicly coupled to the internalflow passage for receiving lubricant during radial expansion and plasticdeformation of the tubular member, wherein the sliding angle is lessthan or equal to 10 degrees. In an exemplary embodiment, the expansiondevice includes a lubricant between the tubular member and the expansiondevice, comprising at least nine components selected from the groupconsisting of: a base oil; metal deactivator; antioxidants; sulfurizednatural oils; phosphate ester; phosphoric acid; viscosity modifier;pour-point depressant; defoamer; and carboxylic acid soaps. In anexemplary embodiment, the expansion device includes, a tapered portionhaving a tapered faceted polygonal outer expansion surface. In anexemplary embodiment, the tubular member has a non-uniform wallthickness and the expansion device includes a tapered portion having atapered faceted polygonal outer expansion surface. In an exemplaryembodiment, the lubricant is stored in a reservoir with electrodes thatare electrically coupled a capacitor in the expansion device and isinjected through at least a portion of the expansion device between thetubular member and the expansion device when the capacitors discharges.In an exemplary embodiment, the expansion device includes a wellborecasing, a pipeline, or a structural support. In an exemplary embodiment,the expansion device includes expansion cone.

A method for radially expanding and plastically deforming the tubularmember has been described that includes positioning an expansion devicehaving one or more expansion surfaces in the interior surface of thetubular member, displacing the expansion device relative to the tubularmember to radially expand and plastically deform the tubular member, andoperating a lubrication device to inject lubricant into an interfacebetween the expansion surface and the tubular member when apredetermined lubricant pressure is reached. In an exemplary embodiment,the lubrication device includes a pump. In an exemplary embodiment, thelubrication device includes a reservoir operably coupled to theexpansion surface for house a lubricant; a means for pressurizing thelubricant; and a means for injecting the lubricant in the reservoir intothe interface when the predetermine pressure is reached. In an exemplaryembodiment, the lubrication device includes a reservoir operably coupledto the expansion surface for house a lubricant; a means for pressurizingthe lubricant, and a valve fluidicly coupled to the reservoir and theexpansion surface for injecting the lubricant into the interface whenthe predetermine pressure is reached. In an exemplary embodiment, thelubrication device includes a reservoir operably coupled to theexpansion surface for house a lubricant, a means for pressurizing thelubricant, a pressure enhancer operably coupled to the reservoir toincrease the pressure on the lubricant in the reservoir, and a valvefluidicly coupled to the reservoir and the expansion surface forinjecting the lubricant into the interface when the predeterminepressure is reached. In an exemplary embodiment, the lubrication deviceincludes a reservoir operably coupled to the expansion surface for housea lubricant, a means for pressurizing the lubricant, a piston operablycoupled to the reservoir, and a valve fluidicly coupled to the reservoirand the expansion surface for injecting the lubricant into the interfacewhen the predetermine pressure is reached. In an exemplary embodiment,the coefficient of friction between the expansion device and the tubularmember during radial expansion and plastic deformation is less than0.08. In an exemplary embodiment, the lubrication device includes thecoefficient of friction between the expansion device and the tubularmember during radial expansion and plastic deformation is in the rangeof 0.02 to 0.05. In an exemplary embodiment, the lubricant includes oilbased lubricants, H1 oil, H2 oil, H3 oil, H4 oil, H5 oil, H6 oil, H7oil, grease, water based lubricants, drilling mud, drilling mud andsolid lubricants, grease combined with a solid lubricant, at least 10%Graphite, or at least 10% Molybdenum Disulfide. In an exemplaryembodiment, the expansion device includes a coating on the expansiondevice. In an exemplary embodiment, the coating may be Phygen film. Inan exemplary embodiment, the expansion device includes a coating on thetubular member. In an exemplary embodiment, the coating on the tubularmember includes PTFE, PTFE based or graphite based. In an exemplaryembodiment, the expansion device includes DC53 material, DC2 material,DC3 material, DC5 material, DC7 material, M2 material, CPM M4 material,10V material, 3V material. In an exemplary embodiment, the expansiondevice includes an REM finish, a processed finish, or a relativelysmooth surface roughness. In an exemplary embodiment, the expansiondevice includes a relatively smooth surface roughness and includesrelatively evenly space oil pockets. In an exemplary embodiment, theexpansion device includes a smooth surface roughness in the range of0.02 to 0.1 micrometers In an exemplary embodiment, the method includesinjecting lubricant through at least two portions of the expansiondevice between the tubular member and the expansion device at twodifferent pressures. In an exemplary embodiment, the expansion deviceincludes a tapered portion with an outer surface, internal flow passagein the tapered portion, at least one circumferential groove having afirst edge and a second edge having with a sliding angle on the outersurface of the tapered portion fluidicly coupled to the internal flowpassage for receiving lubricant during radial expansion and plasticdeformation of the tubular member, wherein the sliding angle is lessthan or equal to 30 degrees and the expansion surfaces are located onthe tapered portion. In an exemplary embodiment, the expansion deviceincludes a tapered portion with an outer surface, internal flow passagein the tapered portion, at least one circumferential groove having afirst edge and a second edge having with a sliding angle on the outersurface of the tapered portion fluidicly coupled to the internal flowpassage for receiving lubricant during radial expansion and plasticdeformation of the tubular member, wherein the sliding angle is lessthan or equal to 10 degrees and the expansion surfaces are located onthe tapered portion. In an exemplary embodiment, the lubricant includesat least nine components selected from the group consisting of: a baseoil; metal deactivator; antioxidants; sulfurized natural oils; phosphateester; phosphoric acid; viscosity modifier; pour-point depressant;defoamer; and carboxylic acid soaps. In an exemplary embodiment, theexpansion device includes a tapered portion having a tapered facetedpolygonal outer expansion surface. In an exemplary embodiment, thetubular member includes a tapered portion having a tapered facetedpolygonal outer expansion surface. In an exemplary embodiment, thelubricant is stored in a reservoir with electrodes that are electricallycoupled a capacitor in the expansion device and the method includescharging the capacitor, discharging the capacitor through theelectrodes, and injecting the lubricant through at least a portion ofthe expansion device between the tubular member and the expansion devicewhen the capacitors discharges. In an exemplary embodiment, the tubularmember includes a wellbore casing, a pipeline or a structural support.In an exemplary embodiment, the expansion device includes an expansioncone.

A lubricant delivery assembly for radially expanding and plasticallydeforming a tubular member has been described that includes an expansioncone having a tapered portion with an outer surface, at least onereservoir for housing a lubricant, at least one circumferential grooveon the outer surface fluidicly connected to the reservoir, and alubricant injection mechanism to force lubricant into the at least onecircumferential groove while radially expanding and plasticallydeforming the tubular member when a predetermined lubricant pressure isreached. In an exemplary embodiment, the lubricant injection mechanismis a valve and the lubricant is drilling fluid received in thereservoir. In an exemplary embodiment, the reservoir is fluidiclyconnected to drilling fluid used to expand the tubular member and thelubricant injection mechanism includes a pressure accelerator receivedwithin the reservoir that separates the drilling fluid and the media.

An expansion device for radially expanding and plastically deforming atubular member has been described that includes a tapered portion withan outer surface, internal flow passage in the tapered portion, and atleast one circumferential groove having a first edge and a second edgewith a predetermined sliding angle on the outer surface of the taperedportion fluidicly coupled to the internal flow passage for receivinglubricant during radial expansion and plastic deformation of the tubularmember, wherein the sliding angle is less than or equal to 30 degrees.

An expansion cone for radially expanding and plastically deforming atubular member has been described that includes a leading portion withan outer surface, internal flow passage in the leading portion, at leastone circumferential groove on the outer surface of the tapered portionfluidicly coupled to the internal flow passage for receiving lubricantduring radial expansion and plastic deformation of the tubular member; atapered portion with an outer surface internal flow passage in thetapered portion and at least one circumferential groove on the outersurface of the tapered portion fluidicly coupled to the internal flowpassage for receiving lubricant during radial expansion and plasticdeformation of the tubular member.

An expansion cone for radially expanding and plastically deforming atubular member has been described that includes a leading portion withan outer surface, internal flow passage in the leading portion, at leastone circumferential groove on the outer surface of the tapered portionfluidicly coupled to the internal flow passage for receiving lubricantduring radial expansion and plastic deformation of the tubular member, atapered portion with an outer surface, internal flow passage in thetapered portion, and at least one circumferential groove on the outersurface of the tapered portion fluidicly coupled to the internal flowpassage for receiving lubricant during radial expansion and plasticdeformation of the tubular member, wherein the lubricant in the leadingportion is at pressure different from the lubricant in the taperedportion.

An expansion cone for radially expanding and plastically deforming atubular member has been described that includes a leading portion withan outer surface, internal flow passage in the leading portion, at leastone circumferential groove on the outer surface of the tapered portionfluidicly coupled to the internal flow passage for receiving lubricantduring radial expansion and plastic deformation of the tubular member, atapered portion with an outer surface, internal flow passage in thetapered portion, and at least one circumferential groove having a firstedge and a second edge with a second predetermined sliding angle on theouter surface of the tapered portion fluidicly coupled to the internalflow passage for receiving lubricant during radial expansion and plasticdeformation of the tubular member; wherein the second sliding angle isless than or equal to 30 degrees.

An expansion cone for radially expanding and plastically deforming atubular member has been described that includes a leading portion withan outer surface, internal flow passage in the leading portion, at leastone circumferential groove on the outer surface of the tapered portionfluidicly coupled to the internal flow passage for receiving lubricantduring radial expansion and plastic deformation of the tubular member, atapered portion with an outer surface, internal flow passage in thetapered portion, and at least one circumferential groove having a firstedge and a second edge with a second predetermined sliding angle on theouter surface of the tapered portion fluidicly coupled to the internalflow passage for receiving lubricant during radial expansion and plasticdeformation of the tubular member, wherein the second sliding angle isless than or equal to 30 degrees.

An expansion cone for radially expanding and plastically deforming atubular member has been described that includes a leading portion withan outer surface, internal flow passage in the leading portion, at leastone circumferential groove on the outer surface of the tapered portionfluidicly coupled to the internal flow passage for receiving lubricantduring radial expansion and plastic deformation of the tubular memberfrom the internal flow passage, a tapered portion with an outer surface,internal flow passage in the tapered portion, and at least onecircumferential groove having a first edge and a second edge with asecond predetermined sliding angle on the outer surface of the taperedportion fluidicly coupled to the internal flow passage for receivinglubricant during radial expansion and plastic deformation of the tubularmember; wherein the second sliding angle is less than or equal to 30degrees, wherein the lubricant in the leading portion is at pressuredifferent from the lubricant in the tapered portion.

A method of reducing the coefficient of friction between the expansiondevice and the tubular member during radial expansion to less than 0.08has been described that includes altering at least one of the elementsselected from the group consisting of: expansion device geometry,expansion device composition, expansion device surface roughness,expansion device texture, expansion device coating, lubricantcomposition, lubricant environmental issues, lubricant frictionalmodifiers, tubular member roughness, and tubular member coating.

A method of reducing the coefficient of friction between the expansiondevice and the tubular member during radial expansion to less than orequal to 0.05 has been describe that includes altering at least one ofthe elements selected from the group consisting of: expansion devicegeometry, expansion device composition, expansion device surfaceroughness, expansion device texture, expansion device coating, lubricantcomposition, lubricant environmental issues, lubricant frictionalmodifiers, tubular member roughness, and tubular member coating.

A method of reducing the coefficient of friction between the expansiondevice and the tubular member during radial expansion to less than orequal to 0.02 has been describe that includes altering at least one ofthe elements selected from the group consisting of: expansion devicegeometry, expansion device composition, expansion device surfaceroughness, expansion device texture, expansion device coating, lubricantcomposition, lubricant environmental issues, lubricant frictionalmodifiers, tubular member roughness, and tubular member coating.

A lubrication system for lubricating an interface between a firstelement and a second element has been described that includes avaporizer proximate to the interface for vaporizing a lubricant toinject the lubricant in the interface. In an exemplary embodiment, thefirst element includes an expansion device and the second elementincludes tubular member during radial expansion and plastic deformationof the tubular member. In an exemplary embodiment, the vaporizerincludes a reservoir for housing a lubricant, and an electric pulsegenerator to create an electric pulse in the lubricant. In an exemplaryembodiment, the electric impulse generator includes at least twoelectrodes housed in the reservoir and at least one capacitorelectrically coupled to the electrode. In an exemplary embodiment, thevaporizer includes a reservoir for housing a lubricant and an magneticpulse generator to create a magnetic pulse in the lubricant. In anexemplary embodiment, the electric impulse generator includes magneticcoil housed in the reservoir. In an exemplary embodiment, the systemincludes an expansion device for positioning in a tubular member andwherein the coefficient of friction between the expansion device and thetubular member during radial expansion and plastic deformation is lessthan 0.08. In an exemplary embodiment, the coefficient of friction is inthe range of 0.02 to 0.05. In an exemplary embodiment, the systemincludes a lubricant between the tubular member and the expansiondevice. In an exemplary embodiment, the lubricant includes oil basedlubricants, H1 oil, H2 oil, H3 oil, H4 oil, H5 oil, H6 oil, H7 oil,grease, water based lubricants, drilling mud, drilling mud and solidlubricants, grease combined with a solid lubricant, at least 10%Graphite, or at least 10% Molybdenum Disulfide. In an exemplaryembodiment, the system includes a coating on the expansion device. In anexemplary embodiment, the coating may be Phygen film. In an exemplaryembodiment, the system includes a coating on the tubular member. In anexemplary embodiment, the coating on the tubular member includes PTFE,PTFE based or graphite based. In an exemplary embodiment, the expansiondevice includes DC53 material, DC2 material, DC3 material, DC5 material,DC7 material, M2 material, CPM M4 material, 10V material, 3V material.In an exemplary embodiment, the expansion device includes an REM finish,a processed finish, or a relatively smooth surface roughness. In anexemplary embodiment, the expansion device includes a relatively smoothsurface roughness and includes relatively evenly space oil pockets. Inan exemplary embodiment, the expansion device includes a smooth surfaceroughness in the range of 0.02 to 0.1 micrometers In an exemplaryembodiment, the lubricant is injected through at least a portion of theexpansion device between the tubular member and the expansion device. Inan exemplary embodiment, the lubricant is injected through at least aportion of the expansion device between the tubular member and theexpansion device when a predetermined pressure is met. In an exemplaryembodiment, the lubricant is injected through at least two portions ofthe expansion device between the tubular member and the expansion deviceat two different pressures. In an exemplary embodiment, the expansiondevice includes a tapered portion with an outer surface, internal flowpassage in the tapered portion and at least one circumferential groovehaving a first edge and a second edge having with a sliding angle on theouter surface of the tapered portion fluidicly coupled to the internalflow passage for receiving lubricant during radial expansion and plasticdeformation of the tubular member, wherein the sliding angle is lessthan or equal to 30 degrees. In an exemplary embodiment, the expansiondevice includes a tapered portion with an outer surface, internal flowpassage in the tapered portion, and at least one circumferential groovehaving a first edge and a second edge having with a sliding angle on theouter surface of the tapered portion fluidicly coupled to the internalflow passage for receiving lubricant during radial expansion and plasticdeformation of the tubular member, wherein the sliding angle is lessthan or equal to 10 degrees. In an exemplary embodiment, the systemincludes a lubricant between the tubular member and the expansiondevice, comprising at least nine components selected from the groupconsisting of: a base oil; metal deactivator; antioxidants; sulfurizednatural oils; phosphate ester; phosphoric acid; viscosity modifier;pour-point depressant; defoamer; and carboxylic acid soaps. In anexemplary embodiment, the expansion device includes, a tapered portionhaving a tapered faceted polygonal outer expansion surface. In anexemplary embodiment, the tubular member has a non-uniform wallthickness and the expansion device includes a tapered; portion having atapered faceted polygonal outer expansion surface. In an exemplaryembodiment, the expansion device includes a wellbore casing, a pipeline,or a structural support. In an exemplary embodiment, the expansiondevice includes expansion cone.

A method for lubricating an interface between a first element and asecond element has been described that includes vaporizing a lubricantproximate to the interface to inject the lubricant in the interface. Inan exemplary embodiment, the first element includes an expansion deviceand the second element includes tubular member during radial expansionand plastic deformation of the tubular member. In an exemplaryembodiment, the method includes housing a lubricant in a reservoirhaving an exit passageway and generating an electric pulse in thereservoir, thereby vaporizing the lubricant and causing a pressure pulseto force lubricant out of the exit passageway. In an exemplaryembodiment, the electric pulse is generated by discharging a capacitorthrough electrodes stored in the lubricant. In an exemplary embodiment,the method includes housing a lubricant in a reservoir having an exitpassageway; and generating a magnetic pulse in the reservoir, therebyvaporizing the lubricant and causing a pressure pulse to force lubricantout of the exit passageway. In an exemplary embodiment, the magneticpulse is generated by current running current through magnetic coilsstored in the lubricant. In an exemplary embodiment, the method includespositioning an expansion device having a first tapered end and a secondend at least partially within the tubular member, displacing theexpansion device relative to the tubular member to radially expand andplastically deform the tubular member; and wherein the coefficient offriction between the expansion device and the tubular member duringradial expansion and plastic deformation is less than 0.08. In anexemplary embodiment, the coefficient of friction is in the range of0.02 to 0.05. In an exemplary embodiment, the method includes injectinglubricant between the tubular member and the expansion device. In anexemplary embodiment, the lubricant includes oil based lubricants, H1oil, H2 oil, H3 oil, H4 oil, H5 oil, H6 oil, H7 oil, grease, water basedlubricants, drilling mud, drilling mud and solid lubricants, greasecombined with a solid lubricant, at least 10% Graphite, or at least 10%Molybdenum Disulfide. In an exemplary embodiment, the method includesapplying a coating on the expansion device prior to positioning withinthe tubular member. In an exemplary embodiment, the coating may bePhygen film. In an exemplary embodiment, the method includes applying acoating on the tubular member prior to positioning the expansion devicewithin the tubular member. In an exemplary embodiment, the coating onthe tubular member includes PTFE, PTFE based or graphite based. In anexemplary embodiment, the expansion device includes DC53 material, DC2material, DC3 material, DC5 material, DC7 material, M2 material, CPM M4material, 10V material, 3V material. In an exemplary embodiment, theexpansion device includes an REM finish, a processed finish, or arelatively smooth surface roughness. In an exemplary embodiment, theexpansion device includes a relatively smooth surface roughness andincludes relatively evenly space oil pockets. In an exemplaryembodiment, the expansion device includes a smooth surface roughness inthe range of 0.02 to 0.1 micrometers In an exemplary embodiment, themethod includes injecting lubricant through at least a portion of theexpansion device between the tubular member and the expansion device. Inan exemplary embodiment, the method includes injecting lubricant throughat least a portion of the expansion device between the tubular memberand the expansion device when a predetermined pressure is met. In anexemplary embodiment, the method includes injecting lubricant through atleast two portions of the expansion device between the tubular memberand the expansion device at two different pressures. In an exemplaryembodiment, the expansion device includes a tapered portion with anouter surface, internal flow passage in the tapered portion and at leastone circumferential groove having a first edge and a second edge havingwith a sliding angle on the outer surface of the tapered portionfluidicly coupled to the internal flow passage for receiving lubricantduring radial expansion and plastic deformation of the tubular member,wherein the sliding angle is less than or equal to 30 degrees. In anexemplary embodiment, the expansion device includes a tapered portionwith an outer surface, internal flow passage in the tapered portion, andat least one circumferential groove having a first edge and a secondedge having with a sliding angle on the outer surface of the taperedportion fluidicly coupled to the internal flow passage for receivinglubricant during radial expansion and plastic deformation of the tubularmember, wherein the sliding angle is less than or equal to 10 degrees.In an exemplary embodiment, the method includes injecting lubricantbetween the tubular member and the expansion device, comprising at leastnine components selected from the group consisting of: a base oil; metaldeactivator; antioxidants; sulfurized natural oils; phosphate ester;phosphoric acid; viscosity modifier; pour-point depressant; defoamer;and carboxylic acid soaps. In an exemplary embodiment, the expansiondevice includes a tapered portion having a tapered faceted polygonalouter expansion surface. In an exemplary embodiment, the expansiondevice includes, a tapered portion having a tapered faceted polygonalouter expansion surface. In an exemplary embodiment, the tubular memberhas a non-uniform wall thickness and the expansion device includes atapered portion having a tapered faceted polygonal outer expansionsurface. In an exemplary embodiment, the expansion device includes awellbore casing, a pipeline, or a structural support. In an exemplaryembodiment, the expansion device includes expansion cone.

A system for lubricating an interface between a first element and asecond element has been described that includes means for vaporizing alubricant proximate to the interface to inject the lubricant in theinterface. In an exemplary embodiment, the area includes an interfacebetween an expansion device and a tubular member during radial expansionand plastic deformation of the tubular member. In an exemplaryembodiment, the means for vaporizing includes a means for housing alubricant in a reservoir having an exit passageway and a means forgenerating an electric pulse in the reservoir, thereby vaporizing thelubricant and causing a pressure pulse to force lubricant out of theexit passageway. In an exemplary embodiment, the electric pulse isgenerated by discharging a capacitor through electrodes stored in thelubricant. In an exemplary embodiment, the means for vaporizing includesmeans for housing a lubricant in a reservoir having an exit passageway,and means for generating a magnetic pulse in the reservoir, therebyvaporizing the lubricant and causing a pressure pulse to force lubricantout of the exit passageway. In an exemplary embodiment, the magneticpulse is generated by current running current through magnetic coilsstored in the lubricant. In an exemplary embodiment, the system includesmeans for positioning an expansion device having a first tapered end anda second end at least partially within a tubular member, means fordisplacing the expansion device relative to the tubular member toradially expand and plastically deform the tubular member, and whereinthe coefficient of friction between the expansion device and the tubularmember during radial expansion and plastic deformation is less than0.08. In an exemplary embodiment, the coefficient of friction is in therange of 0.02 to 0.05. In an exemplary embodiment, the system, includesa means for injecting lubricant between the tubular member and theexpansion device. In an exemplary embodiment, the lubricant includes oilbased lubricants, H1 oil, H2 oil, H3 oil, H4 oil, H5 oil, H6 oil, H7oil, grease, water based lubricants, drilling mud, drilling mud andsolid lubricants, grease combined with a solid lubricant, at least 10%Graphite, or at least 10% Molybdenum Disulfide. In an exemplaryembodiment, the system includes a means for applying a coating on theexpansion device prior to positioning within the tubular member. In anexemplary embodiment, the coating may be Phygen film. In an exemplaryembodiment, the method includes applying a coating on the tubular memberprior to positioning the expansion device within the tubular member. Inan exemplary embodiment, the coating on the tubular member includesPTFE, PTFE based or graphite based. In an exemplary embodiment, theexpansion device includes DC53 material, DC2 material, DC3 material, DC5material, DC7 material, M2 material, CPM M4 material, 10V material, 3Vmaterial. In an exemplary embodiment, the expansion device includes anREM finish, a processed finish, or a relatively smooth surfaceroughness. In an exemplary embodiment, the expansion device includes arelatively smooth surface roughness and includes relatively evenly spaceoil pockets. In an exemplary embodiment, the expansion device includes asmooth surface roughness in the range of 0.02 to 0.1 micrometers In anexemplary embodiment, the system includes a means for injectinglubricant through at least a portion of the expansion device between thetubular member and the expansion device. In an exemplary embodiment, thesystem includes a means for injecting lubricant through at least aportion of the expansion device between the tubular member and theexpansion device when a predetermined pressure is met. In an exemplaryembodiment, the system includes a means for injecting lubricant throughat least two portions of the expansion device between the tubular memberand the expansion device at two different pressures. In an exemplaryembodiment, the expansion device includes a tapered portion with anouter surface, internal flow passage in the tapered portion and at leastone circumferential groove having a first edge and a second edge havingwith a sliding angle on the outer surface of the tapered portionfluidicly coupled to the internal flow passage for receiving lubricantduring radial expansion and plastic deformation of the tubular member,wherein the sliding angle is less than or equal to 30 degrees. In anexemplary embodiment, the expansion device includes a tapered portionwith an outer surface, internal flow passage in the tapered portion, andat least one circumferential groove having a first edge and a secondedge having with a sliding angle on the outer surface of the taperedportion fluidicly coupled to the internal flow passage for receivinglubricant during radial expansion and plastic deformation of the tubularmember, wherein the sliding angle is less than or equal to 10 degrees.In an exemplary embodiment, the system includes a means for injectinglubricant between the tubular member and the expansion device,comprising at least nine components selected from the group consistingof: a base oil; metal deactivator; antioxidants; sulfurized naturaloils; phosphate ester; phosphoric acid; viscosity modifier; pour-pointdepressant; defoamer; and carboxylic acid soaps. In an exemplaryembodiment, the expansion device includes a tapered portion having atapered faceted polygonal outer expansion surface. In an exemplaryembodiment, the expansion device includes, a tapered portion having atapered faceted polygonal outer expansion surface. In an exemplaryembodiment, the tubular member has a non-uniform wall thickness and theexpansion device includes a tapered portion having a tapered facetedpolygonal outer expansion surface. In an exemplary embodiment, theexpansion device includes a wellbore casing, a pipeline, or a structuralsupport. In an exemplary embodiment, the expansion device includesexpansion cone.

A system for radially expanding and plastically deforming a tubularmember has been described that includes an expansion device positionedin the tubular member, and wherein the coefficient of friction betweenthe expansion device and the tubular member during radial expansion andplastic deformation is less than 0.08 and wherein lubricant is stored ina reservoir with a magnetic coil in the expansion device and is injectedthrough at least a portion of the expansion device between the tubularmember and the expansion device when current runs through the magneticcoil.

A system for radially expanding and plastically deforming a tubularmember has been described that includes an expansion device positionedin the tubular member, and wherein the coefficient of friction betweenthe expansion device and the tubular member during radial expansion andplastic deformation is less than 0.08 and wherein lubricant is stored ina reservoir and injected through at least a portion of the expansiondevice between the tubular member and the expansion device whenvaporized.

A method of radially expanding and plastically deforming a tubularmember has been described that includes positioning an expansion devicehaving a first tapered end and a second end at least partially withinthe tubular member, displacing the expansion device relative to thetubular member to radially expand and plastically deform the tubularmember, and injecting a lubricant stored in a reservoir with a magneticcoil in the expansion device through at least a portion of the expansiondevice between the tubular member and the expansion device when currentruns through the magnetic coil, and wherein the coefficient of frictionbetween the expansion device and the tubular member during radialexpansion and plastic deformation is less than 0.08.

A method of radially expanding and plastically deforming a tubularmember has been described that includes positioning an expansion devicehaving a first tapered end and a second end at least partially withinthe tubular member, displacing the expansion device relative to thetubular member to radially expand and plastically deform the tubularmember, and vaporizing a lubricant stored in a reservoir in theexpansion device and injecting it through at least a portion of theexpansion device between the tubular member and the expansion device,and wherein the coefficient of friction between the expansion device andthe tubular member during radial expansion and plastic deformation isless than 0.08.

A system for radially expanding and plastically deforming a tubularmember has been described that includes means for positioning anexpansion device having a first tapered end and a second end at leastpartially within the tubular member, means for displacing the expansiondevice relative to the tubular member to radially expand and plasticallydeform the tubular member, and wherein the coefficient of frictionbetween the expansion device and the tubular member during radialexpansion and plastic deformation is less than 0.08 and whereinlubricant is stored in a reservoir and injected through at least aportion of the expansion device between the tubular member and theexpansion device when vaporized.

A system for radially expanding and plastically deforming a tubularmember has been described that includes means for positioning anexpansion device having a first tapered end and a second end at leastpartially within the tubular member, means for displacing the expansiondevice relative to the tubular member to radially expand and plasticallydeform the tubular member; and wherein the coefficient of frictionbetween the expansion device and the tubular member during radialexpansion and plastic deformation is less than 0.08 and whereinlubricant is stored in a reservoir with a magnetic coil in the expansiondevice and is injected through at least a portion of the expansiondevice between the tubular member and the expansion device when currentruns through the magnetic coil.

A system for radially expanding and plastically deforming a tubularmember has been described that includes means for positioning anexpansion device having a first tapered end and a second end at leastpartially within the tubular member, means for displacing the expansiondevice relative to the tubular member to radially expand and plasticallydeform the tubular member, and means for vaporizing lubricant stored ina reservoir and injecting it through at least a portion of the expansiondevice between the tubular member and the expansion device, wherein thecoefficient of friction between the expansion device and the tubularmember during radial expansion and plastic deformation is less than0.08.

A system for radially expanding and plastically deforming a tubularmember has been described that includes means for positioning anexpansion device having a first tapered end and a second end at leastpartially within the tubular member, means for displacing the expansiondevice relative to the tubular member to radially expand and plasticallydeform the tubular member, and means for vaporizing lubricant stored ina reservoir and injecting it through at least a portion of the expansiondevice between the tubular member and the expansion device, wherein thecoefficient of friction between the expansion device and the tubularmember during radial expansion and plastic deformation is less than 0.08and wherein means for vaporizes comprises a magnetic coil in thereservoir operably connected to a power source.

An expansion device for radially expanding and plastically deforming thetubular member has been described that includes one or more expansionsurfaces on the expansion device for engaging the interior surface ofthe tubular member during the radial expansion and plastic deformationof the tubular member; and a lubrication device operably coupled to theexpansion surface for injecting lubricant into an interface between theexpansion surface and the tubular member during the radial expansion andplastic deformation of the tubular member when a predetermined lubricantpressure is reached, wherein lubricant is stored in a reservoir in thelubrication device and injected through at least a portion of theexpansion device between the tubular member and the expansion devicewhen vaporized.

An expansion device for radially expanding and plastically deforming thetubular member has been described that includes one or more expansionsurfaces on the expansion device for engaging the interior surface ofthe tubular member during the radial expansion and plastic deformationof the tubular member, and a lubrication device operably coupled to theexpansion surface for injecting lubricant into an interface between theexpansion surface and the tubular member during the radial expansion andplastic deformation of the tubular member when a predetermined lubricantpressure is reached, and wherein lubricant is stored in a reservoir witha magnetic coil in the expansion device and is injected through at leasta portion of the expansion device between the tubular member and theexpansion device when current runs through the magnetic coil.

A method for radially expanding and plastically deforming the tubularmember has been described that includes positioning an expansion devicehaving one or more expansion surfaces in the interior surface of thetubular member, displacing the expansion device relative to the tubularmember to radially expand and plastically deform the tubular member,operating a lubrication device to inject lubricant into an interfacebetween the expansion surface and the tubular member when apredetermined lubricant pressure is reached, and wherein lubricant isstored in a reservoir in the lubrication device and injected through atleast a portion of the expansion device between the tubular member andthe expansion device when vaporized.

A method for radially expanding and plastically deforming the tubularmember has been described that includes positioning an expansion devicehaving one or more expansion surfaces in the interior surface of thetubular member; displacing the expansion device relative to the tubularmember to radially expand and plastically deform the tubular member,operating a lubrication device to inject lubricant into an interfacebetween the expansion surface and the tubular member when apredetermined lubricant pressure is reached, and wherein lubricant isstored in a reservoir with a magnetic coil in the expansion device andis injected through at least a portion of the expansion device betweenthe tubular member and the expansion device when current runs throughthe magnetic coil.

A lubricant delivery assembly for radially expanding and plasticallydeforming a tubular member has been described that includes an expansioncone having a tapered portion with an outer surface, at least onereservoir for housing a lubricant, at least one circumferential grooveon the outer surface fluidicly connected to the reservoir and alubricant injection mechanism to force lubricant into the at least onecircumferential groove while radially expanding and plasticallydeforming the tubular member when a predetermined lubricant pressure isreached. In an exemplary embodiment, the lubricant is stored in areservoir with a magnetic coil in the expansion device and is injectedthrough at least a portion of the expansion device between the tubularmember and the expansion device when current runs through the magneticcoil. In an exemplary embodiment, the lubricant is stored in a reservoirin the lubrication device and injected through at least a portion of theexpansion device between the tubular member and the expansion devicewhen vaporized. In an exemplary embodiment, the lubricant is stored in areservoir with electrodes that are electrically coupled a capacitor inthe expansion device and is injected through at least a portion of theexpansion device between the tubular member and the expansion devicewhen the capacitors discharges.

An expansion device for radially expanding and plastically deforming atubular member has been described that includes a tapered portion withan outer surface, internal flow passage in the tapered portion, and atleast one circumferential groove having a first edge and a second edgewith a predetermined sliding angle on the outer surface of the taperedportion fluidicly coupled to the internal flow passage for receivinglubricant during radial expansion and plastic deformation of the tubularmember, wherein the sliding angle is less than or equal to 30 degrees.In an exemplary embodiment, the lubricant is stored in a reservoir witha magnetic coil in the expansion device and is injected through at leasta portion of the expansion device between the tubular member and theexpansion device when current runs through the magnetic coil. In anexemplary embodiment, the lubricant is stored in a reservoir in thelubrication device and injected through at least a portion of theexpansion device between the tubular member and the expansion devicewhen vaporized. In an exemplary embodiment, the lubricant is stored in areservoir with electrodes that are electrically coupled a capacitor inthe expansion device and is injected through at least a portion of theexpansion device between the tubular member and the expansion devicewhen the capacitors discharges.

An expansion cone for radially expanding and plastically deforming atubular member has been described that includes a leading portion withan outer surface, internal flow passage in the leading portion, at leastone circumferential groove on the outer surface of the tapered portionfluidicly coupled to the internal flow passage for receiving lubricantduring radial expansion and plastic deformation of the tubular member, atapered portion with an outer surface, internal flow passage in thetapered portion and at least one circumferential groove on the outersurface of the tapered portion fluidicly coupled to the internal flowpassage for receiving lubricant during radial expansion and plasticdeformation of the tubular member. In an exemplary embodiment, thelubricant is stored in a reservoir with a magnetic coil in the expansiondevice and is injected through at least a portion of the expansiondevice between the tubular member and the expansion device when currentruns through the magnetic coil. In an exemplary embodiment, thelubricant is stored in a reservoir in the lubrication device andinjected through at least a portion of the expansion device between thetubular member and the expansion device when vaporized. In an exemplaryembodiment, the lubricant is stored in a reservoir with electrodes thatare electrically coupled a capacitor in the expansion device and isinjected through at least a portion of the expansion device between thetubular member and the expansion device when the capacitors discharges.

An expansion cone for radially expanding and plastically deforming atubular member has been described that includes a leading portion withan outer surface, internal flow passage in the leading portion, at leastone circumferential groove on the outer surface of the tapered portionfluidicly coupled to the internal flow passage for receiving lubricantduring radial expansion and plastic deformation of the tubular member, atapered portion with an outer surface, internal flow passage in thetapered portion, at least one circumferential groove on the outersurface of the tapered portion fluidicly coupled to the internal flowpassage for receiving lubricant during radial expansion and plasticdeformation of the tubular member, wherein the lubricant in the leadingportion is at pressure different from the lubricant in the taperedportion. In an exemplary embodiment, the lubricant is stored in areservoir with a magnetic coil in the expansion device and is injectedthrough at least a portion of the expansion device between the tubularmember and the expansion device when current runs through the magneticcoil. In an exemplary embodiment, the lubricant is stored in a reservoirin the lubrication device and injected through at least a portion of theexpansion device between the tubular member and the expansion devicewhen vaporized. In an exemplary embodiment, the lubricant is stored in areservoir with electrodes that are electrically coupled a capacitor inthe expansion device and is injected through at least a portion of theexpansion device between the tubular member and the expansion devicewhen the capacitors discharges.

An expansion cone for radially expanding and plastically deforming atubular member has been described that includes a leading portion withan outer surface, internal flow passage in the leading portion, at leastone circumferential groove on the outer surface of the tapered portionfluidicly coupled to the internal flow passage for receiving lubricantduring radial expansion and plastic deformation of the tubular member, atapered portion with an outer surface, internal flow passage in thetapered portion, at least one circumferential groove having a first edgeand a second edge with a second predetermined sliding angle on the outersurface of the tapered portion fluidicly coupled to the internal flowpassage for receiving lubricant during radial expansion and plasticdeformation of the tubular member; wherein the second sliding angle isless than or equal to 30 degrees. In an exemplary embodiment, thelubricant is stored in a reservoir with a magnetic coil in the expansiondevice and is injected through at least a portion of the expansiondevice between the tubular member and the expansion device when currentruns through the magnetic coil. In an exemplary embodiment, thelubricant is stored in a reservoir in the lubrication device andinjected through at least a portion of the expansion device between thetubular member and the expansion device when vaporized. In an exemplaryembodiment, the lubricant is stored in a reservoir with electrodes thatare electrically coupled a capacitor in the expansion device and isinjected through at least a portion of the expansion device between thetubular member and the expansion device when the capacitors discharges.

An expansion cone for radially expanding and plastically deforming atubular member has been described that includes a leading portion withan outer surface internal flow passage in the leading portion, at leastone circumferential groove on the outer surface of the tapered portionfluidicly coupled to the internal flow passage for receiving lubricantduring radial expansion and plastic deformation of the tubular member, atapered portion with an outer surface, internal flow passage in thetapered portion, at least one circumferential groove having a first edgeand a second edge with a second predetermined sliding angle on the outersurface of the tapered portion fluidicly coupled to the internal flowpassage for receiving lubricant during radial expansion and plasticdeformation of the tubular member; wherein the second sliding angle isless than or equal to 30 degrees. In an exemplary embodiment, thelubricant is stored in a reservoir with a magnetic coil in the expansiondevice and is injected through at least a portion of the expansiondevice between the tubular member and the expansion device when currentruns through the magnetic coil. In an exemplary embodiment, thelubricant is stored in a reservoir in the lubrication device andinjected through at least a portion of the expansion device between thetubular member and the expansion device when vaporized. In an exemplaryembodiment, the lubricant is stored in a reservoir with electrodes thatare electrically coupled a capacitor in the expansion device and isinjected through at least a portion of the expansion device between thetubular member and the expansion device when the capacitors discharges.

An expansion cone for radially expanding and plastically deforming atubular member has been described that includes a leading portion withan outer surface, internal flow passage in the leading portion, at leastone circumferential groove on the outer surface of the tapered portionfluidicly coupled to the internal flow passage for receiving lubricantduring radial expansion and plastic deformation of the tubular memberfrom the internal flow passage, a tapered portion with an outer surface,internal flow passage in the tapered portion, at least onecircumferential groove having a first edge and a second edge with asecond predetermined sliding angle on the outer surface of the taperedportion fluidicly coupled to the internal flow passage for receivinglubricant during radial expansion and plastic deformation of the tubularmember; wherein the second sliding angle is less than or equal to 30degrees, wherein the lubricant in the leading portion is at pressuredifferent from the lubricant in the tapered portion. In an exemplaryembodiment, the lubricant is stored in a reservoir with a magnetic coilin the expansion device and is injected through at least a portion ofthe expansion device between the tubular member and the expansion devicewhen current runs through the magnetic coil. In an exemplary embodiment,the lubricant is stored in a reservoir in the lubrication device andinjected through at least a portion of the expansion device between thetubular member and the expansion device when vaporized. In an exemplaryembodiment, the lubricant is stored in a reservoir with electrodes thatare electrically coupled a capacitor in the expansion device and isinjected through at least a portion of the expansion device between thetubular member and the expansion device when the capacitors discharges.

A method of reducing the coefficient of friction between the expansiondevice and the tubular member during radial expansion to less than 0.08has been described that includes altering at least one of the elementsselected from the group consisting of: expansion device geometry,expansion device composition, expansion device surface roughness,expansion device texture, expansion device coating, lubricantcomposition, lubricant environmental issues, lubricant frictionalmodifiers, tubular member roughness, and tubular member coating. In anexemplary embodiment, the lubricant is stored in a reservoir with amagnetic coil in the expansion device and is injected through at least aportion of the expansion device between the tubular member and theexpansion device when current runs through the magnetic coil. In anexemplary embodiment, the lubricant is stored in a reservoir in thelubrication device and injected through at least a portion of theexpansion device between the tubular member and the expansion devicewhen vaporized. In an exemplary embodiment, the lubricant is stored in areservoir with electrodes that are electrically coupled a capacitor inthe expansion device and is injected through at least a portion of theexpansion device between the tubular member and the expansion devicewhen the capacitors discharges.

A system for radially expanding and plastically deforming a tubularmember having a non-uniform wall thickness has been disclosed thatincludes an expansion device having one or more expansion surfaces and atapered portion having a tapered faceted polygonal outer expansionsurface in the interior surface of the tubular member. In an alternateembodiment, the system includes lubricant between the tubular member andthe expansion device. In an exemplary embodiment, the lubricant includesoil based lubricants, H1 oil, H2 oil, H3 oil, H4 oil, H5 oil, H6 oil, H7oil, grease, water based lubricants, drilling mud, drilling mud andsolid lubricants, grease combined with a solid lubricant, at least 10%Graphite, or at least 10% Molybdenum Disulfide. In an exemplaryembodiment, the system includes a coating on the expansion device. In anexemplary embodiment, the coating may be Phygen film. In an exemplaryembodiment, the system includes a coating on the tubular member. In anexemplary embodiment, the coating on the tubular member includes PTFE,PTFE based or graphite based. In an exemplary embodiment, the expansiondevice includes DC53 material, DC2 material, DC3 material, DC5 material,DC7 material, M2 material, CPM M4 material, 10V material, 3V material.In an exemplary embodiment, the expansion device includes an REM finish,a processed finish, or a relatively smooth surface roughness. In anexemplary embodiment, the expansion device includes a relatively smoothsurface roughness and includes relatively evenly space oil pockets. Inan exemplary embodiment, the expansion device includes a smooth surfaceroughness in the range of 0.02 to 0.1 micrometers In an exemplaryembodiment, the lubricant is injected through at least a portion of theexpansion device between the tubular member and the expansion device. Inan exemplary embodiment, the lubricant is injected through at least aportion of the expansion device between the tubular member and theexpansion device when a predetermined pressure is met. In an exemplaryembodiment, the lubricant is injected through at least two portions ofthe expansion device between the tubular member and the expansion deviceat two different pressures. In an exemplary embodiment, the expansiondevice includes a tapered portion with an outer surface, internal flowpassage in the tapered portion and at least one circumferential groovehaving a first edge and a second edge having with a sliding angle on theouter surface of the tapered portion fluidicly coupled to the internalflow passage for receiving lubricant during radial expansion and plasticdeformation of the tubular member, wherein the sliding angle is lessthan or equal to 30 degrees. In an exemplary embodiment, the expansiondevice includes a tapered portion with an outer surface, internal flowpassage in the tapered portion, and at least one circumferential groovehaving a first edge and a second edge having with a sliding angle on theouter surface of the tapered portion fluidicly coupled to the internalflow passage for receiving lubricant during radial expansion and plasticdeformation of the tubular member, wherein the sliding angle is lessthan or equal to 10 degrees. In an exemplary embodiment, the systemincludes a lubricant between the tubular member and the expansiondevice, comprising at least nine components selected from the groupconsisting of: a base oil; metal deactivator; antioxidants; sulfurizednatural oils; phosphate ester; phosphoric acid; viscosity modifier;pour-point depressant; defoamer; and carboxylic acid soaps. In anexemplary embodiment, the lubricant is stored in a reservoir withelectrodes that are electrically coupled a capacitor in the expansiondevice and is injected through at least a portion of the expansiondevice between the tubular member and the expansion device when thecapacitors discharges. In an exemplary embodiment, the expansion deviceincludes a wellbore casing, a pipeline, or a structural support. In anexemplary embodiment, the expansion device includes expansion cone.

A method of radially expanding and plastically deforming a tubularmember having a non-uniform wall thickness has been described thatincludes positioning an expansion device having one or more expansionsurfaces and a tapered portion having a tapered faceted polygonal outerexpansion surface in the interior surface of the tubular member, anddisplacing the expansion device relative to the tubular member toradially expand and plastically deform the tubular member. In anexemplary embodiment, the method includes injecting lubricant betweenthe tubular member and the expansion device. In an exemplary embodiment,the lubricant includes oil based lubricants, H1 oil, H2 oil, H3 oil, H4oil, H5 oil, H6 oil, H7 oil, grease, water based lubricants, drillingmud, drilling mud and solid lubricants, grease combined with a solidlubricant, at least 10% Graphite, or at least 10% Molybdenum Disulfide.In an exemplary embodiment, the method includes applying a coating onthe expansion device prior to positioning within the tubular member. Inan exemplary embodiment, the coating may be Phygen film. In an exemplaryembodiment, the method includes applying a coating on the tubular memberprior to positioning the expansion device within the tubular member. Inan exemplary embodiment, the coating on the tubular member includesPTFE, PTFE based or graphite based. In an exemplary embodiment, theexpansion device includes DC53 material, DC2 material, DC3 material, DC5material, DC7 material, M2 material, CPM M4 material, 10V material, 3Vmaterial. In an exemplary embodiment, the expansion device includes anREM finish, a processed finish, or a relatively smooth surfaceroughness. In an exemplary embodiment, the expansion device includes arelatively smooth surface roughness and includes relatively evenly spaceoil pockets. In an exemplary embodiment, the expansion device includes asmooth surface roughness in the range of 0.02 to 0.1 micrometers In anexemplary embodiment, the method includes injecting lubricant through atleast a portion of the expansion device between the tubular member andthe expansion device. In an exemplary embodiment, the method includesinjecting lubricant through at least a portion of the expansion devicebetween the tubular member and the expansion device when a predeterminedpressure is met. In an exemplary embodiment, the method includesinjecting lubricant through at least two portions of the expansiondevice between the tubular member and the expansion device at twodifferent pressures. In an exemplary embodiment, the expansion deviceincludes a tapered portion with an outer surface, internal flow passagein the tapered portion and at least one circumferential groove having afirst edge and a second edge having with a sliding angle on the outersurface of the tapered portion fluidicly coupled to the internal flowpassage for receiving lubricant during radial expansion and plasticdeformation of the tubular member, wherein the sliding angle is lessthan or equal to 30 degrees. In an exemplary embodiment, the expansiondevice includes a tapered portion with an outer surface, internal flowpassage in the tapered portion, and at least one circumferential groovehaving a first edge and a second edge having with a sliding angle on theouter surface of the tapered portion fluidicly coupled to the internalflow passage for receiving lubricant during radial expansion and plasticdeformation of the tubular member, wherein the sliding angle is lessthan or equal to 10 degrees. In an exemplary embodiment, the methodincludes injecting lubricant between the tubular member and theexpansion device, comprising at least nine components selected from thegroup consisting of: a base oil; metal deactivator; antioxidants;sulfurized natural oils; phosphate ester, phosphoric acid; viscositymodifier; pour-point depressant; defoamer; and carboxylic acid soaps. Inan exemplary embodiment, the lubricant is stored in a reservoir withelectrodes that are electrically coupled a capacitor in the expansiondevice and is injected through at least a portion of the expansiondevice between the tubular member and the expansion device when thecapacitors discharges. In an exemplary embodiment, the expansion deviceincludes a wellbore casing, a pipeline, or a structural support. In anexemplary embodiment, the expansion device includes expansion cone.

An expansion device for radially expanding and plastically deforming atubular member has been described that includes a tapered portion withan outer surface, internal flow passage in the tapered portion, and atleast one circumferential groove having a first edge and a second edgewith a predetermined sliding angle on the outer surface of the taperedportion fluidicly coupled to the internal flow passage for receivinglubricant during radial expansion and plastic deformation of the tubularmember, wherein the sliding angle is less than or equal to 30 degrees;and wherein lubricant is stored in a reservoir with electrodes that areelectrically coupled a capacitor in the expansion device and is injectedthrough at least a portion of the expansion device between the tubularmember and the expansion device when the capacitors discharges.

An expansion cone for radially expanding and plastically deforming atubular member has been described that includes a leading portion withan outer surface, internal flow passage in the leading portion, at leastone circumferential groove on the outer surface of the tapered portionfluidicly coupled to the internal flow passage for receiving lubricantduring radial expansion and plastic deformation of the tubular member, atapered portion with an outer surface; internal flow passage in thetapered portion; and at least one circumferential groove on the outersurface of the tapered portion fluidicly coupled to the internal flowpassage for receiving lubricant during radial expansion and plasticdeformation of the tubular member, wherein lubricant is stored in areservoir with electrodes that are electrically coupled a capacitor inthe expansion device and is injected through at least a portion of theexpansion device between the tubular member and the expansion devicewhen the capacitors discharges.

An expansion cone for radially expanding and plastically deforming atubular member has been described that includes a leading portion withan outer surface, internal flow passage in the leading portion, at leastone circumferential groove on the outer surface of the tapered portionfluidicly coupled to the internal flow passage for receiving lubricantduring radial expansion and plastic deformation of the tubular member, atapered portion with an outer surface, internal flow passage in thetapered portion; and at least one circumferential groove on the outersurface of the tapered portion fluidicly coupled to the internal flowpassage for receiving lubricant during radial expansion and plasticdeformation of the tubular member, wherein the lubricant in the leadingportion is at pressure different from the lubricant in the taperedportion, and wherein lubricant is stored in a reservoir with electrodesthat are electrically coupled a capacitor in the expansion device and isinjected through at least a portion of the expansion device between thetubular member and the expansion device when the capacitors discharges.

An expansion cone for radially expanding and plastically deforming atubular member has been described that includes a leading portion withan outer surface, internal flow passage in the leading portion, at leastone circumferential groove on the outer surface of the tapered portionfluidicly coupled to the internal flow passage for receiving lubricantduring radial expansion and plastic deformation of the tubular member, atapered portion with an outer surface, internal flow passage in thetapered portion, and at least one circumferential groove having a firstedge and a second edge with a second predetermined sliding angle on theouter surface of the tapered portion fluidicly coupled to the internalflow passage for receiving lubricant during radial expansion and plasticdeformation of the tubular member; wherein the second sliding angle isless than or equal to 30 degrees, wherein lubricant is stored in areservoir with electrodes that are electrically coupled a capacitor inthe expansion device and is injected through at least a portion of theexpansion device between the tubular member and the expansion devicewhen the capacitors discharges.

An expansion cone for radially expanding and plastically deforming atubular member has been described that includes a leading portion withan outer surface, internal flow passage in the leading portion, at leastone circumferential groove on the outer surface of the tapered portionfluidicly coupled to the internal flow passage for receiving lubricantduring radial expansion and plastic deformation of the tubular member, atapered portion with an outer surface, internal flow passage in thetapered portion; and at least one circumferential groove having a firstedge and a second edge with a second predetermined sliding angle on theouter surface of the tapered portion fluidicly coupled to the internalflow passage for receiving lubricant during radial expansion and plasticdeformation of the tubular member; wherein the second sliding angle isless than or equal to 30 degrees., wherein lubricant is stored in areservoir with electrodes that are electrically coupled a capacitor inthe expansion device and is injected through at least a portion of theexpansion device between the tubular member and the expansion devicewhen the capacitors discharges.

An expansion cone for radially expanding and plastically deforming atubular member has been described that includes a leading portion withan outer surface, internal flow passage in the leading portion, at leastone circumferential groove on the outer surface of the tapered portionfluidicly coupled to the internal flow passage for receiving lubricantduring radial expansion and plastic deformation of the tubular memberfrom the internal flow passage. a tapered portion with an outer surface,internal flow passage in the tapered portion; and at least onecircumferential groove having a first edge and a second edge with asecond predetermined sliding angle on the outer surface of the taperedportion fluidicly coupled to the internal flow passage for receivinglubricant during radial expansion and plastic deformation of the tubularmember; wherein the second sliding angle is less than or equal to 30degrees, wherein the lubricant in the leading portion is at pressuredifferent from the lubricant in the tapered portion, and whereinlubricant is stored in a reservoir with electrodes that are electricallycoupled a capacitor in the expansion device and is injected through atleast a portion of the expansion device between the tubular member andthe expansion device when the capacitors discharges.

A system for radially expanding and plastically deforming a tubularmember having non-uniform wall thickness has been described thatincludes means for positioning an expansion device having one or moreexpansion surfaces and a tapered portion having a tapered facetedpolygonal outer expansion surface in the interior surface of the tubularmember; and means for displacing the expansion device relative to thetubular member to radially expand and plastically deform the tubularmember.

A system for radially expanding and plastically deforming a tubularmember has been described that includes an expansion cone of D53material having a phygen coating and an REM finish and H1 oil whereinthe tubular member is coated with PTFE.

A method for manufacturing an expandable member used to complete astructure by radially expanding and plastically deforming the expandablemember has been described that includes forming the expandable memberfrom a steel alloy comprising a charpy energy of at least about 90ft-lbs.

An expandable member for use in completing a structure by radiallyexpanding and plastically deforming the expandable member has beendescribed that includes a steel alloy comprising a charpy energy of atleast about 90 ft-lbs.

A structural completion positioned within a structure has been describedthat includes one or more radially expanded and plastically deformedexpandable members positioned within the structure; wherein one or moreof the radially expanded and plastically deformed expandable members arefabricated from a steel alloy comprising a charpy energy of at leastabout 90 ft-lbs.

A method for manufacturing an expandable member used to complete astructure by radially expanding and plastically deforming the expandablemember has been described that includes forming the expandable memberfrom a steel alloy comprising a weight percentage of carbon of less thanabout 0.08%.

An expandable member for use in completing a wellbore by radiallyexpanding and plastically deforming the expandable member at a downholelocation in the wellbore has been described that includes a steel alloycomprising a weight percentage of carbon of less than about 0.08%.

A structural completion has been described that includes one or moreradially expanded and plastically deformed expandable members positionedwithin the wellbore; wherein one or more of the radially expanded andplastically deformed expandable members are fabricated from a steelalloy comprising a weight percentage of carbon of less than about 0.08%.

A method for manufacturing an expandable member used to complete astructure by radially expanding and plastically deforming the expandablemember has been described that includes forming the expandable memberfrom a steel alloy comprising a weight percentage of carbon of less thanabout 0.20% and a charpy V-notch impact toughness of at least about 6joules.

An expandable member for use in completing a structure by radiallyexpanding and plastically deforming the expandable member has beendescribed that includes a steel alloy comprising a weight percentage ofcarbon of less than about 0.20% and a charpy V-notch impact toughness ofat least about 6 joules.

A structural completion has been described that includes one or moreradially expanded and plastically deformed expandable members; whereinone or more of the radially expanded and plastically deformed expandablemembers are fabricated from a steel alloy comprising a weight percentageof carbon of less than about 0.20% and a charpy V-notch impact toughnessof at least about 6 joules.

A method for manufacturing an expandable member used to complete astructure by radially expanding and plastically deforming the expandablemember has been described that includes forming the expandable memberfrom a steel alloy comprising the following ranges of weightpercentages: C, from about 0.002 to about 0.08; Si, from about 0.009 toabout 0.30; Mn, from about 0.10 to about 1.92; P, from about 0.004 toabout 0.07; S, from about 0.0008 to about 0.006; Al, up to about 0.04;N, up to about 0.01; Cu, up to about 0.3; Cr, up to about 0.5; Ni, up toabout 18; Nb, up to about 0.12; Ti, up to about 0.6; Co, up to about 9;and Mo, up to about 5.

An expandable member for use in completing a structure by radiallyexpanding and plastically deforming the expandable member has beendescribed that includes a steel alloy comprising the following ranges ofweight percentages: C, from about 0.002 to about 0.08; Si, from about0.009 to about 0.30; Mn, from about 0.10 to about 1.92; P, from about0.004 to about 0.07; S, from about 0.0008 to about 0.006; Al, up toabout 0.04; N, up to about 0.01; Cu, up to about 0.3; Cr, up to about0.5; Ni, up to about 18; Nb, up to about 0.12; Ti, up to about 0.6; Co,up to about 9; and Mo, up to about 5.

A structural completion has been described that includes one or moreradially expanded and plastically deformed expandable members; whereinone or more of the radially expanded and plastically deformed expandablemembers are fabricated from a steel alloy comprising the followingranges of weight percentages: C, from about 0.002 to about 0.08; Si,from about 0.009 to about 0.30; Mn, from about 0.10 to about 1.92; P,from about 0.004 to about 0.07; S, from about 0.0008 to about 0.006; Al,up to about 0.04; N, up to about 0.01; Cu, up to about 0.3; Cr, up toabout 0.5; Ni, up to about 18; Nb, up to about 0.12; Ti, up to about0.6; Co, up to about 9; and Mo, up to about 5.

A method for manufacturing an expandable tubular member used to completea structure by radially expanding and plastically deforming theexpandable member has been described that includes forming theexpandable tubular member with a ratio of the of an outside diameter ofthe expandable tubular member to a wall thickness of the expandabletubular member ranging from about 12 to 22.

An expandable member for use in completing a structure by radiallyexpanding and plastically deforming the expandable member has beendescribed that includes an expandable tubular member with a ratio of theof an outside diameter of the expandable tubular member to a wallthickness of the expandable tubular member ranging from about 12 to 22.

A structural completion has been described that includes one or moreradially expanded and plastically deformed expandable members positionedwithin the structure; wherein one or more of the radially expanded andplastically deformed expandable members are fabricated from anexpandable tubular member with a ratio of the of an outside diameter ofthe expandable tubular member to a wall thickness of the expandabletubular member ranging from about 12 to 22.

A method of constructing a structure has been described that includesradially expanding and plastically deforming an expandable member;wherein an outer portion of the wall thickness of the radially expandedand plastically deformed expandable member comprises tensile residualstresses.

A structural completion has been described that includes one or moreradially expanded and plastically deformed expandable members; whereinan outer portion of the wall thickness of one or more of the radiallyexpanded and plastically deformed expandable members comprises tensileresidual stresses.

A method of constructing a structure using an expandable tubular memberhas been described that includes strain aging the expandable member; andthen radially expanding and plastically deforming the expandable member.

A method for manufacturing a tubular member used to complete a wellboreby radially expanding the tubular member at a downhole location in thewellbore has been described that includes forming a steel alloycomprising a concentration of carbon between approximately 0.002% and0.08% by weight of the steel alloy.

A method of increasing a collapse strength of a tubular member after aradial expansion and plastic deformation of the tubular member using anexpansion device has been described that includes reducing a coefficientof friction between the tubular member and the expansion device duringthe radial expansion and plastic deformation of the tubular member; andreducing a ratio of a diameter of the tubular member to a wall thicknessof the tubular member. In an exemplary embodiment, the coefficient offriction is less than 0.075.

In an exemplary embodiment, the ratio of the diameter of the tubularmember to a wall thickness of the tubular member is less than 21.6. Inan exemplary embodiment, the collapse strength of a tubular member afterthe radial expansion and plastic deformation of the tubular member usingan expansion device is greater than 5000 ksi.

A system for radially expanding and plastically deforming a tubularmember has been described that includes a tubular member, and anexpansion device positioned within the tubular member, wherein thecoefficient of friction between the tubular member and the expansiondevice is less than 0.075, and wherein the ratio of the diameter of thetubular member to a wall thickness of the tubular member is less than21.6.

A method of radially expanding and plastically deforming a tubularmember using an expansion device has been described that includesquenching and tempering the tubular member; positioning the tubularmember within a preexisting structure; and radially expanding andplastically deforming the tubular member. In an exemplary embodiment,the yield strength of the tubular member ranges from about 76.8 ksi to88.8 ksi. In an exemplary embodiment, the ratio of the yield strength tothe tensile strength of the tubular member ranges from about 0.82 to0.86. In an exemplary embodiment, the longitudinal elongation of thetubular member prior to failure ranges from about 14.8% to 22.0%. In anexemplary embodiment, the width reduction of the tubular member prior tofailure ranges from about 32% to 44.0%. In an exemplary embodiment, thewidth thickness reduction of the tubular member prior to failure rangesfrom about 41.0% to 45%. In an exemplary embodiment, the anisotropy ofthe tubular member ranges from about 0.65 to 1.03. In an exemplaryembodiment, the absorbed energy in the longitudinal direction of thetubular member ranges from about 125 to 145 ft-lbs. In an exemplaryembodiment, the absorbed energy in the transverse direction of thetubular member ranges from about 59 to 59 ft-lbs. In an exemplaryembodiment, the absorbed energy in a welded portion of the tubularmember ranges from about 174 to 176 ft-lbs. In an exemplary embodiment,a flared expansion of an end of tubular member ranged from about 42 to52%. In an exemplary embodiment, the tubular member comprises, by weightpercentage: 0.27 C, 0.14 Si; 1.28 Mn; 0.009 P; 0.005 S; and 0.14 Cr. Inan exemplary embodiment, the quenching of the tubular member is providedat about 97° C.; and the tempering the tubular member is provided atabout 67° C.

A radially expandable and plastically deformable tubular member has beendescribed that includes a yield strength ranging from about 76.8 ksi to88.8 ksi, a ratio of the yield strength to a tensile strength of thetubular member ranging from about 0.82 to 0.86, a longitudinalelongation of the tubular member prior to failure ranging from about14.8% to 22.0%, a width reduction of the tubular member prior to failureranging from about 32% to 44.0%, a width thickness reduction of thetubular member prior to failure ranges from about 41.0% to 45%, and ananisotropy of the tubular member ranges from about 0.65 to 1.03. In anexemplary embodiment, an absorbed energy in the longitudinal directionof the tubular member ranges from about 125 to 145 ft-lbs. In anexemplary embodiment, the absorbed energy in the transverse direction ofthe tubular member ranges from about 59 to 59 ft-lbs. In an exemplaryembodiment, the absorbed energy in a welded portion of the tubularmember ranges from about 174 to 176 ft-lbs. In an exemplary embodiment,a flared expansion of an end of tubular member ranged from about 42 to52%. In an exemplary embodiment, the tubular member comprises, by weightpercentage: 0.27 C, 0.14 Si; 1.28 Mn; 0.009 P; 0.005 S; and 0.14 Cr.

A radially expandable and plastically deformable tubular member has beendescribed that includes: a yield strength ranging from about 40.0 ksi to100.0 ksi; a ratio of the yield strength to a tensile strength of thetubular member ranging from about 0.40 to 0.85; a longitudinalelongation of the tubular member prior to failure ranging from at leastabout 22.0 to 35.0%; a width reduction of the tubular member prior tofailure ranging from at least about 30.0% to 45.0%; a width thicknessreduction of the tubular member prior to failure ranges from at leastabout 30.0% to 45.0%; and an anisotropy of the tubular member rangesfrom at least about 0.65 to 1.50. In an exemplary embodiment, anabsorbed energy in the longitudinal direction of the tubular member isat least about 80 ft-lbs. In an exemplary embodiment, the absorbedenergy in the transverse direction of the tubular member is at leastabout 60 ft-lbs. In an exemplary embodiment, the absorbed energy in awelded portion of the tubular member is at least about 60 ft-lbs. In anexemplary embodiment, a flared expansion of an end of tubular memberranges from at least about 45 to 75%.

A method of manufacturing a tubular member has been described thatincludes fabricating a tubular member; positioning the tubular memberwithin a preexisting structure; radially expanding and plasticallydeforming the tubular member within the preexisting structure; andbaking the tubular member within the preexisting structure. In anexemplary embodiment, the preexisting structure comprises a wellbore. Inan exemplary embodiment, the fabricated tubular member comprises a dualphase steel pipe. In an exemplary embodiment, the fabricated tubularmember comprises a microstructure comprising about 15 to 30% martensite;and ferrite. In an exemplary embodiment, the fabricated tubular membercomprises, by weight percentage: 0.1 C, 1.2 Mn; and 0.3 Si. In anexemplary embodiment, the fabricated tubular member comprises a TRIPsteel pipe. In an exemplary embodiment, fabricating the tubular membercomprises: cold rolling the tubular member; and inter critical annealingthe tubular member. In an exemplary embodiment, the fabricated tubularmember comprises a dual phase steel pipe. In an exemplary embodiment,prior to the cold rolling, the fabricated tubular member comprises amicrostructure comprising ferrite and pearlite. In an exemplaryembodiment, the inter critical annealing is performed at about 75° C. Inan exemplary embodiment, after the inter critical annealing, thefabricated tubular member comprises a microstructure comprising ferriteand at least one of pearlite and austentite. In an exemplary embodiment,the method further comprising: cooling the tubular member after theinter critical annealing. In an exemplary embodiment, after the cooling,the tubular member comprises a microstructure comprising martensite. Inan exemplary embodiment, the baking is provided at about 10° C. to 250C. In an exemplary embodiment, following at least a portion of thebaking, the tubular member comprises a bake-hardened portion. In anexemplary embodiment, following at least a portion of the baking, thetubular member comprises a stress-relieved portion. In an exemplaryembodiment, following at least a portion of the baking, the tubularmember comprises a bake-hardened portion and a stress-relieved portion.In an exemplary embodiment, the cold rolling comprises: allowing thetubular member to cool over time from a first temperature to a secondtemperature along a temperature versus time curve; and at a plurality ofstages along the curve, deforming the tubular member. In an exemplaryembodiment, at a first stage along the curve, insoluble precipitateswithin the tubular member retard austentite growth. In an exemplaryembodiment, at a first stage along the curve, deformation of the tubularmember promotes precipitation. In an exemplary embodiment, at a secondstage along the curve, insoluble precipitates within the tubular memberinhibit recrystallization. In an exemplary embodiment, at a second stagealong the curve, austentite grains are conditioned.

It is understood that variations may be made in the foregoing withoutdeparting from the scope of the invention. For example, the teachings ofthe present illustrative embodiments may be used to provide a wellborecasing, a pipeline, or a structural support. Furthermore, the elementsand teachings of the various illustrative embodiments may be combined inwhole or in part in some or all of the illustrative embodiments. Inaddition, one or more of the elements and teachings of the variousillustrative embodiments may be omitted, at least in part, and/orcombined, at least in part, with one or more of the other elements andteachings of the various illustrative embodiments.

Although illustrative embodiments of the invention have been shown anddescribed, a wide range of modification, changes and substitution iscontemplated in the foregoing disclosure. In some instances, somefeatures of the present invention may be employed without acorresponding use of the other features. Accordingly, it is appropriatethat the appended claims be construed broadly and in a manner consistentwith the scope of the invention.

1. A method of forming a tubular liner within a preexisting structure,comprising: positioning a tubular assembly within the preexistingstructure; and radially expanding and plastically deforming the tubularassembly within the preexisting structure; wherein, prior to the radialexpansion and plastic deformation of the tubular assembly, apredetermined portion of the tubular assembly has a lower yield pointthan another portion of the tubular assembly.
 2. An expandable tubularmember comprising a steel alloy comprising, by weight percentage thefollowing: 0.065 to 0.18% C, 0.006 to 1.44% Mn, 0.006 to 0.02% P, 0.001to 0.004% S, 0.24 to 0.45% Si, up to 0.16% Cu, 0.01 to 9.1% Ni, and 0.02to 18.7% Cr.
 3. An expandable tubular member, wherein the yield point ofthe expandable tubular member is at most about 46.9 to 61.7 ksi prior toa radial expansion and plastic deformation; and wherein the yield pointof the expandable tubular member is at least about 65.9 to 74.4 ksiafter the radial expansion and plastic deformation.
 4. An expandabletubular member, wherein a yield point of the expandable tubular memberafter a radial expansion and plastic deformation is at least about 5.8to 40% greater than the yield point of the expandable tubular memberprior to the radial expansion and plastic deformation.
 5. An expandabletubular member, wherein the anisotropy of the expandable tubular member,prior to the radial expansion and plastic deformation, ranges from about1.04 to at least about 1.92.
 6. An expandable tubular member, whereinthe expandability coefficient of the expandable tubular member, prior tothe radial expansion and plastic deformation, is greater than 0.12. 7.An expandable tubular member, wherein the expandability coefficient ofthe expandable tubular member is greater than the expandabilitycoefficient of another portion of the expandable tubular member.
 8. Anexpandable tubular member, wherein the tubular member has a higherductility and a lower yield point prior to a radial expansion andplastic deformation than after the radial expansion and plasticdeformation.
 9. A method of radially expanding and plastically deforminga tubular assembly comprising a first tubular member coupled to a secondtubular member, comprising: radially expanding and plastically deformingthe tubular assembly within a preexisting structure; and using lesspower to radially expand each unit length of the first tubular memberthan to radially expand each unit length of the second tubular member.10. A method of manufacturing a tubular member, comprising: processing atubular member until the tubular member is characterized by one or moreintermediate characteristics; positioning the tubular member within apreexisting structure; and processing the tubular member within thepreexisting structure until the tubular member is characterized one ormore final characteristics.
 11. An apparatus, comprising: an expandabletubular assembly; and an expansion device coupled to the expandabletubular assembly; wherein a predetermined portion of the expandabletubular assembly has a lower yield point than another portion of theexpandable tubular assembly.
 12. An expandable tubular member, wherein ayield point of the expandable tubular member after a radial expansionand plastic deformation is at least about 5.8% greater than the yieldpoint of the expandable tubular member prior to the radial expansion andplastic deformation.
 13. A method of determining the expandability of aselected tubular member, comprising: determining an anisotropy value forthe selected tubular member; determining a strain hardening value forthe selected tubular member; and multiplying the anisotropy value timesthe strain hardening value to generate an expandability value for theselected tubular member.
 14. A method of radially expanding andplastically deforming tubular members, comprising: selecting a tubularmember; determining an anisotropy value for the selected tubular member;determining a strain hardening value for the selected tubular member;multiplying the anisotropy value times the strain hardening value togenerate an expandability value for the selected tubular member; and ifthe anisotropy value is greater than 0.12, then radially expanding andplastically deforming the selected tubular member.
 15. A radiallyexpandable tubular member apparatus comprising: a first tubular member;a second tubular member engaged with the first tubular member forming ajoint; and a sleeve overlapping and coupling the first and secondtubular members at the joint; wherein, prior to a radial expansion andplastic deformation of the apparatus, a predetermined portion of theapparatus has a lower yield point than another portion of the apparatus.16. A method of joining radially expandable tubular members comprising:providing a first tubular member; engaging a second tubular member withthe first tubular member to form a joint; providing a sleeve; mountingthe sleeve for overlapping and coupling the first and second tubularmembers at the joint; wherein the first tubular member, the secondtubular member, and the sleeve define a tubular assembly; and radiallyexpanding and plastically deforming the tubular assembly; wherein, priorto the radial expansion and plastic deformation, a predetermined portionof the tubular assembly has a lower yield point than another portion ofthe tubular assembly.
 17. An expandable tubular member wherein, if thecarbon content of the tubular member is less than or equal to 0.12percent, then the carbon equivalent value for the tubular member is lessthan 0.21; and wherein, if the carbon content of the tubular member isgreater than 0.12 percent, then the carbon equivalent value for thetubular member is less than 0.36.
 18. A method of selecting tubularmembers for radial expansion and plastic deformation, comprising:selecting a tubular member from a collection of tubular member;determining a carbon content of the selected tubular member; determininga carbon equivalent value for the selected tubular member; if the carboncontent of the selected tubular member is less than or equal to 0.12percent and the carbon equivalent value for the selected tubular memberis less than 0.21, then determining that the selected tubular member issuitable for radial expansion and plastic deformation; and if the carboncontent of the selected tubular member is greater than 0.12 percent andthe carbon equivalent value for the selected tubular member is less than0.36, then determining that the selected tubular member is suitable forradial expansion and plastic deformation.
 19. An expandable tubularmember, comprising: a tubular body; wherein a yield point of an innertubular portion of the tubular body is less than a yield point of anouter tubular portion of the tubular body.
 20. A method of manufacturingan expandable tubular member, comprising: providing a tubular member;heat treating the tubular member; and quenching the tubular member;wherein following the quenching, the tubular member comprises amicrostructure comprising a hard phase structure and a soft phasestructure.
 21. A system for radially expanding and plastically deforminga tubular member, comprising: an expansion device positioned in thetubular member; and wherein the coefficient of friction between theexpansion device and the tubular member during radial expansion andplastic deformation is less than 0.08.
 22. A method of radiallyexpanding and plastically deforming a tubular member, comprising:positioning an expansion device having a first tapered end and a secondend at least partially within the tubular member; displacing theexpansion device relative to the tubular member to radially expand andplastically deform the tubular member; and wherein the coefficient offriction between the expansion device and the tubular member duringradial expansion and plastic deformation is less than 0.08.
 23. Alubricant for injecting in an interface between a tubular member and anexpansion device, comprising, by weight percentage: 64.25% to 90.89%canola oil; 0.02% to 0.05% tolyltriazole; 0.5% to 1.0% aminicantioxidant; 0.5% to 2.0% phenolic antioxidant; 4% to 12% sulfurizednatural oil or sulferized lard oil; 4% to 12% phosphate ester; 0.4% to1.5 phosphoric acid; 0.08% to 1.5% styrene hydrocarbon polymer; 0.1% to0.5% alkyl ester copolymer; 0.01% to 0.2% silicon based antifoam agent;and 1% to 5% carbozylic acid soap.
 24. An expansion device for radiallyexpanding and plastically deforming the tubular member, comprising: oneor more expansion surfaces on the expansion device for engaging theinterior surface of the tubular member during the radial expansion andplastic deformation of the tubular member; and a lubrication deviceoperably coupled to the expansion surface for injecting lubricant intoan interface between the expansion surface and the tubular member duringthe radial expansion and plastic deformation of the tubular member whena predetermined pressure for lubrication is reached.
 25. An expansiondevice for radially expanding and plastically deforming a tubularmember, comprising: a tapered portion with an outer surface; internalflow passage in the tapered portion; and at least one circumferentialgroove having a first edge and a second edge with a predeterminedsliding angle on the outer surface of the tapered portion fluidiclycoupled to the internal flow passage for receiving lubricant duringradial expansion and plastic deformation of the tubular member, whereinthe sliding angle is less than or equal to 30 degrees.
 26. A method forradially expanding and plastically deforming the tubular member,comprising: positioning an expansion device having one or more expansionsurfaces in the interior surface of the tubular member; displacing theexpansion device relative to the tubular member to radially expand andplastically deform the tubular member; and operating a lubricationdevice to inject lubricant into an interface between the expansionsurface and the tubular member when a predetermined lubricant pressureis reached.
 27. A method of reducing the coefficient of friction betweenthe expansion device and the tubular member during radial expansion toless than 0.08, comprising: altering at least one of the elementsselected from the group consisting of: expansion device geometry,expansion device composition, expansion device surface roughness,expansion device texture, expansion device coating, lubricantcomposition, lubricant environmental issues, lubricant frictionalmodifiers, tubular member roughness, and tubular member coating.
 28. Alubrication system for lubricating an interface between a first elementand a second element, comprising: a vaporizer proximate to the interfacefor vaporizing a lubricant to inject the lubricant in the interface. 29.A method for lubricating an interface between a first element and asecond element, comprising: vaporizing a lubricant proximate to theinterface to inject the lubricant in the interface.
 30. A system forradially expanding and plastically deforming a tubular member,comprising: an expansion device positioned in the tubular member; andwherein the coefficient of friction between the expansion device and thetubular member during radial expansion and plastic deformation is lessthan 0.08 and wherein lubricant is stored in a reservoir with a magneticcoil in the expansion device and is injected through at least a portionof the expansion device between the tubular member and the expansiondevice when current runs through the magnetic coil.
 31. A system forradially expanding and plastically deforming a tubular member,comprising: an expansion device positioned in the tubular member; andwherein the coefficient of friction between the expansion device and thetubular member during radial expansion and plastic deformation is lessthan 0.08 and wherein lubricant is stored in a reservoir and injectedthrough at least a portion of the expansion device between the tubularmember and the expansion device when vaporized.
 32. A method of radiallyexpanding and plastically deforming a tubular member, comprising:positioning an expansion device having a first tapered end and a secondend at least partially within the tubular member; displacing theexpansion device relative to the tubular member to radially expand andplastically deform the tubular member; and injecting a lubricant storedin a reservoir with a magnetic coil in the expansion device through atleast a portion of the expansion device between the tubular member andthe expansion device when current runs through the magnetic coil, andwherein the coefficient of friction between the expansion device and thetubular member during radial expansion and plastic deformation is lessthan 0.08.
 33. A method of radially expanding and plastically deforminga tubular member, comprising: positioning an expansion device having afirst tapered end and a second end at least partially within the tubularmember; displacing the expansion device relative to the tubular memberto radially expand and plastically deform the tubular member; andvaporizing a lubricant stored in a reservoir in the expansion device andinjecting it through at least a portion of the expansion device betweenthe tubular member and the expansion device, and wherein the coefficientof friction between the expansion device and the tubular member duringradial expansion and plastic deformation is less than 0.08.
 34. Alubricant delivery assembly for radially expanding and plasticallydeforming a tubular member, comprising: an expansion device having atapered portion with an outer surface, at least one reservoir forhousing a lubricant, at least one circumferential groove on the outersurface fluidicly connected to the reservoir; and a lubricant injectionmechanism to force lubricant into the at least one circumferentialgroove while radially expanding and plastically deforming the tubularmember when a predetermined lubricant pressure is reached.
 35. A methodof reducing the coefficient of friction between the expansion device andthe tubular member during radial expansion to less than 0.08,comprising: altering at least one of the elements selected from thegroup consisting of: expansion device geometry, expansion devicecomposition, expansion device surface roughness, expansion devicetexture, expansion device coating, lubricant composition, lubricantenvironmental issues, lubricant frictional modifiers, tubular memberroughness, and tubular member coating.